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FILE NAME: Garlock (GAR) DATE: 1946 Nov DOC#: GAR018 DOCUMENT DESCRIPTION: Trade Journal Advertisements - Southern Power & Industry ste tti >f yo3. A ftep !onsul|| suggesg L equiPff )nts irfe >my. 9** m tig 2ialistsj| vice in dationMtneersf| in r ; by inj or bj cilitiesj iuippe4 --steeM neriesM bcetera.1t ER, l94A|g Eugene W . O'Brien M anaging D irector Francis C . Smith, Editor Hunter R. Hughes, Jr. Associate E ditor Richard L. Priest South-western E ditor W . E. Coogier Production Manager Business Representatives K. L. Rogers, 18 E a s t 48th St., Room 1904, New York 17, N. Y.-- Phone, P la z a 8-2565. William K. H offm an, 28 Bowdoin St., Maplewood, N. J .-- Phone So. O range 2-2484. Maynard L. D urham , 6? Coving ton Road, B uffalo 16, N. Y.-- Phone, Am herst 6332. A. E. C. Sm ith, 206 A uditorium Building, Cleveland 14, Ohio --Phone, Cherry 7352. P. 0 . E. Johnson, 168 N orth M ichigan Ave., Chicago 1, 111.-- Phone, C e n tra l 4131. L. B. Chappell, A uditorium Bldg., 42T w e s t 5 th S t., Los Ange les, C alif. -- Phone, T ucker 6363. Richard L. Priess, 1341 Liberty Bank Bldg., D allas, Texas.-- Pbone, C entral 7673. Annual Subscription-- $1.00 Canada-- $1.50 ; Foreign $2.00 -- 9-- Published Monthly by W R. c. SMITH PUBLISHING C O . Publishers also of : Cotton, Elec trical South, Southern Hardware, bouthem Autom otive Journal, Southern Building Supplies, y* J. Rooke. P re s id e n t; R. ] sm ith, Executive Vice-President 4* 'Ll M cAllister, V ice-President *? Jw. O'B rien. V ice-President f- C. Sm ith, V ice-President C. Cook, V ice-P resident: 0. i fcbarpless. T re a s u r e r; A. F. Ro erts. Secretary. Editorial rn d Executive O ffices SP.A N T b u il d in g ATLANTA, GEORGIA Mechanical Handling of Cross-Ties, by A .M. Deiters.. ____ __.. . . . . . . ; A Good Lunch Helps, by Francis C . Smith:, . . 40 /? 46 ii Profits in Plant Layout, by Gregory M. Dexter .............................. .., 49 Progress in Candy Making, by R. A . Brock and F. W .Hayward . 58 Hygienic Importance of Dust, by N. V. Hendricks . .............. 61 Centrifugal Boiler Feed Pumps, by Igor J . Karassik.......... ............ . . . . 65 Labor Turnover, by Philip Panfield ................................................. .......... 74 Damage by Hy Ash Erosion, by Harry M. Sp rin g................... 78 > Electric Circuit Troubles, by Thomas T r a il........ ........ .... . ............. 84 A History of Power, by Carl J. Eckhardt, Jr. .......................... . . 86 PRACTICAL DISCUSSION Routing Operation Improved . . . . . . . 92 T ight Bolt-Threads ................................. 94 < Magnetic S treet C le a n e r '.., . . . . . . . 92 L adder Aids Maintenance . . . . i .......... 94 >Y Simple A ir Manifold . . . . . . . ........... 92 Freezing Aids R e p a i r s ............... 94 Reading Meters and Gauges . . . . . . . . 94 DEPARTMENTS ............- ' / X FACTS AND T R EN D S............................... 5 INDUS T R Y /S P E A K S .................................. 39 BUY ERS' IN FO R M A TIO N ........ ......... 8 TIM ELY COMMENTS....................... : . . . 3 7 NEWS 0/ / THE MONTH........................ '96 NEW E Q U IP M E N T ........ ..........................114 INDEX TO A D V E R T IS E R S ............. 134 %JS\. At left -- Section through m ill exhauster showing new shrouded fan wheel with whizzer" blades. J . 1% B C-E PRODUCTS INCLNtf ALL TYPES OF BOILERS, FURNACES. PULVERIZED FUEL SYSTEMS AND STOKERS; ALSO SUPERHEATERS, ECONOMIZERS AND AIR HEATERS 14 SOUTHERN POWER & INDUSTRY for NOVEMBER, 19** ( AV.-` ,;,Yt.' In 1935 the C-E Raymond Bowl .Mill came into the steam-power field with design and operating ad vantages that revolutionized previous concepts of coal pulverization. It had a wide capacity range. It handled wet coal with great facility. It was rugged, accessible and easily maintained. The mill ran quietly and povver consumption was low. In consequence, the Bowl Mill won immediate and widespread acceptance among plant engineers -- more than a million lb pr hr of grinding capacity was ordered within five years. Today, the Bowl Mill with all of its initial ad vantages, offers several new improvements, among which the following are of major importance: CP Flat-Bottom Bowl --increases the response of the mill to load changes by eliminating any inactive area where coal can remain in the mill; also avoids any tendency of heavy, abrasive material such as pyrites, to accumulate in the bottom of the bowl. The Whizzer Wheel --a new exhauster wheel design which greatly increases the life of exhauster blades. A shrouded wheel carries heavily constructed "whizzer" blades which bypass a por tion of the air-coal mixture directly to the exhauster outlet. In service this has doubled the life of exhauster blades --in some cases more than doubled it. 0 New, Wear-Resisting Materials --are now being used for ex hauster liners and deflectors, resulting in greatly increased life of these parts. Center Feed --where conditions permit, larger Bowl Mills can now be arranged for center feed which assures a freer flow of coal to the mill and serves to equalize wear on grinding parts. Thus 1946 finds the C-E Raymond Bowl Mill, after more than 10 years at the top of its field, still adding refinements in design and materials that make it better than ever before. 2 00 M A D I S O N AVENUE, NEW Y OR K 16, N. SUTHERN POWER & INDUSTRY for NOVEMBER, 1946 G arlock 150 S p iral packing, illustrated. Coil-- G a r l o c k 125 R in g s--G arlock 200 Low in maintenance cost because it gives such long, dependable service. Costly shut downs for frequent repacking are avoided. Man hours and machine hours are saved. Use G a r l o c k 150 on piston rods of engines, pumps, compres sors, etc., against steam pressures up to 300 lbs. The Garlock Packing Company, Palmyra, New York In Canada: The Garlock Packing Company of Canada Ltd., Montreal, Que. SOUTHERN POWER & INDUSTRY for NOVEMBER, 1946 27 Industrial Hygiene Importance of Dust By N . V . Hendricks Chief Engineer Industrial Hygiene Service, Georgia Department of Public Health Nearly all types of m odem industry a r e concerned with dust and its control. Courtesy M. S. A . Co. F IG . I. T H E M ID GE T 1MPINGER USED FOR C l l e c t i n g a t m o s - tiate between the PHERIC DUST SAMPLES. o r i g i n of these materials, a defi nition of them is in THE annual cost to industry from u n c o n t r o l l e d dust amounts to a staggering figure. many cases the problem of dust is dismissed by management as only a nuisance. In other plants, the recovery of certain dusts is eco nomically sound, especially where the particulate matter may con tain precious metals or may carry valuable processing stock. Aside horn any nuisance or economic loss resulting from the escape of dust there are certain dust ex posures which may result in acute health hazards. This is especial ly true of dusts containing a high Percentage of free silica, asbestos, or other toxic materials. Where health considerations are involved in such exposures, legal aspects Present themselves. In most states ^here occupational diseases are compensable, specific coverage is Eiven to those disabilities resultlr>g from the inhalation of silica dugt. Definitions Many times true dusts are conMsed with fumes, smokes, mists, and fogs. In order to differen- order. DUSTS are formed by the re duction of earthy materials and Inare usually produced by such ope rations as crushing, grinding, buffing, etc. The particle size of dusts may vary considerably, ranging from sub-microscopic to visible. FUMES are formed by conden sation and sublimation. Chemi cally, they are metallic and are usually the oxides of such metals as zinc, and lead. The particle size is usually below one micron. Smoke comes from the burning of organic material and its par ticle size is usually less than onehalf micron. Misis and Fogs result from the condensation of water vapor on suitable nuclei, and the particle size will vary with given con ditions. General Properiies As a substance is reduced in particle size, there are certain general properties of the material which are changed. On breaking up a solid into finely divided par ticles, the surface area is greatly enlarged and therefore the space occupied is greatly increased. As an example, a piece of quartz one centimeter on each side when crushed to where the particles of one micron in size will present a system containing 10" number of particles. The total surface area will be 6 square meters. If these dust particles are dispersed onto the atmosphere in such manner that the concentration will be 100 million particles per cubic foot, the space occupied by this dis persed system will be 10 thousand cubic feet. The chemical activity of a solid is considerably increased by a reduction in particle size. Thus the rate of oxidation is increased as is evidenced by occasional dis astrous dust explosions. The phe nomena of adsorption becomes more important as gases are more easily adsorbed on the surface of the smaller particle. From the standpoint of health hazards resulting from dust ex posures, the physiological proper ties of dust vary somewhat with the particle size. It is an accepted fact that with exposures to silica dust, the smaller the particle size, the greater the hazard. Physiological Response Drinker has summarized the re actions resulting from the inhala- SUTHERN POWER & INDUSTRY for NOVEMBER, 1946 tion of dust by classifying the re sponse into four groups. These are: (a) Pneumoconiosis--The dusts producing this type reaction are harmful only when inhaled. The principal materials producing this type reaction are free silica and asbestos dust. On inhalation, these two materials produce specific lung pathology and from the standpoint of disability, present the most important of the dust ex posures. (b) Toxic Reaction--(As poison ing by lead, cadmium or radium) These materials produce harmful effects when taken into the body both by inhalation and ingestion. With reference to lead and its compounds which may be present in the atmosphere as particulate matter, it has been fairly well established that entrance into the body oy inhalation is more im portant mode of entry than the same material taken by mouth. This is primarily due to the fact that when such materials are tak en into the body by inhalation, the major portion is taken into the blood stream, whereas, a consider able part of that taken by mouth is removed by certain organs of the body. (c) Metal Fume Fevers--These conditions result from the inhala tion of finely divided fume par ticles. The importance of metal fume fever has been brought to the attention of industry by the great amount of welding which has been an important industrial tool for the past few years. Where burning or welding is done on sur faces which have been galvanized, the problem of metal fumes be comes immediately important. This is also a problem in foundries'* where the pouring of brass i3 done. i' (d) Allergy--This type reaction"' is in general produced by pollen and certain organic dusts. - Common Industrial Dusts Carbonates are usually combin ed with either calcium or magnesium. They normally occur in ; nature as calcite and magnasite or as dolomite, which contains both magnesium and calcium as the carbonate. Limestone and marble c o n t a i n considerable T amounts of these carbonates, as i do the materials from which ce ment is made. Due to the solubility in body fluids, these materials are removed when taken into the body by inhalation. The presence of car bon dioxide in such fluids is an important factor influencing their solubility. The same thing applies to the presence of carbon dioxide in water which comes into contact with these materials. In the pres ence of carbon dioxide the car bonate is converted to the more soluble bicarbonate, thus adding to the ease with which it is remov- . ed by solution. Experimental and practical ob servations on carbonate dust in dicate that these materials are not harmful when taken into the body by inhalation. This is probably due to the fact that they are easi ly removed due to their solubility. Sulfates are common industrial materials and this general class may be illustrated by gypsum, which is calcium sulfate. This is a common material and is widely used in many industrial opera tions. It is generally considered that this type material is non-tox ic and does not present any par ticular problem from a health standpoint. Oxides vary considerably in their physiological reaction. In general the nature of the reaction will be dependent on the type metal from which the oxide is de rived. Where such metals are specifically toxic, as would be the case with arsenic or lead, a spe cific toxic reaction could be ex pected from the inhalation of the oxide. However, other oxides ap pear to be relatively harmless, particularly where the metal is of a non-specific type. This is true of iron oxide. The mining of iron results in the exposure of a great number of men to the oxides of 62 SOUTHERN POWER & INDUSTRY for NOVEMBER, 1946 ma%v. or iasite> tati?} n aa| an<t? "able? s, asi 1 bol mov'^ y by]' ear-J* s an' their], plies',; )xide] ntactrese car nore no'' FIG. 3. GE OR GI A KAOLIN OUST MAGNIFICA* TION 130X . this metal. However, it appears that exposure to the dust of iron does not produce pathology un less such exposure is accompanied by the pressure of free silica. The mining of coal results in exposure to coal dust which con tains a high percentage of carbon. Detailed studies of exposure to coal dust have been made by the U. S. Public Health Service and other agencies. It has been found that, in general, coal dust is re tained in the lungs only when such dust contains a high per centage of free silica. Although coal dust may be deposited in the lungs of exposed individuals, the condition resulting is usually not considered disabling unless silica is present. Silicates make up an important class of industrial materials and are used principally in the pro duction of ceramics and similar materials. Talc, kaolin, mica, clays, etc., are chemically silicates and their widespread industrial ap plication results in a great number of employees being exposed to this type dust. With the excep tion of asbestos, which is a silicate, this general class of materials does not appear to produce a disabling condition, except in isolated cases, when taken into the body by in halation. Asbestos is the only silicate known at the present time which produces a lung pathology com parable with that resulting from exposure to* silica dust. Of all the dust found in indus try, probably the most important is free silica or silicon dioxide. It occurs in the form of quartz, flint, sandstone, and chert; and is as- FIG. 4. QUARTZ DUST (SI Oo) MAGNIFICA- TION I30X. sociated with many other miner als and ores. The disabling con dition resulting from the inhala tion of free silica is known as silicosis and has long been a problem with industries such as stone cutting, granite, foundry, abrasive, and the like, where sili ca is used in processing. There are relatively few industrial ope rations which might result in di rect exposure to pure silica dust. The importance of silica lies in its association with other materials. As an example, in foundry opera tions the dust generally will con tain clay and materials of a nonsilicious character, so that the ac tual percentage of free silica may be relatively low. This is also true in exposures to coal, iron oxide, and the mining of ores. When hard rock or silica is present, these dusts become important mainly due to the presence of silica rather than to the inherent properties of the parent material. Factors Influencing Hazards In evaluating the exposure to a dust there are several factors which should be taken into con sideration. The duration of ex posure is important, as it will in dicate in a general way the total amount of dust which might be expected to have entered the body. Obviously other factors enter into such an evaluation of total dusti ness, and these will be discussed later. History of past exposure is important. This is particularly true where an individual is ex posed to silica dust. This point is of extreme importance to industry due to the fact that a worker may have contracted silicosis under a FIG. 5. CALCIUM CARBONATE DUST MAG NIFICATION I30X. previous employment. Where such a condition exists, the desirability of preemployment examination is obvious. The c o n c e n t r a t i o n of dust breathed is important as this, within certain limits, will deter mine the possibility of develop ment of dust diseases. Consider able research and practical obser vations have been made in the field of dust exposures to corre late clinical findings with atmos pheric concentrations. For free silica, asbestos, and some of the other materials, fairly definite standards have been established. The nature of dust is important primarily from the standpoint of free silica content. This is par ticularly true of mixed dusts which constitute the majority of industrial exposures. The volume of air breathed enters into the picture as it directly influenc es the amount of dust which will be taken into the body. The rate of respiration or amount of air breathed in general will be de termined by the physical effort required on the particular job. Where heavy work is being done, naturally an individual will re quire more ventilation than where less physical effort is involved. Dust Measurements In addition to the factors in fluencing dust hazards, it is neces sary to make direct dust measure ments in order to obtain a true evaluation of any dust exposure. Such measurements are made by the actual collection of dust sam ples, the counting of the dust par ticles, and by the identification of the materials making up the dis SOUTHERN POWER & INDUSTRY for NOVEMBER, 1946 63 persed system. For the collection of dust samples, several instru ments may be employed. Much of the early work done on the control of silicosis in the mining areas of South Africa was carried out with the Konimeter. This instrument has been used some in this country, however, it has not met with the popularity which is enjoyed by certain other methods. From the standpoint of collecting efficiency, the electro static precipitator is probably the choice instrument, however, most of the work done on correlating atmospheric dust concentrations with medical findings has been based on samples collected and counted by the Greenburg-Smith technique. The collecting device employed is an impinger unit which samples at the rate of one cubic foot per minute. Counting by this technique is done under light field. The per centage of free silica in a dust sample is usually determined by either chemical or petrographic methods. Perm issible concentrations of dust have been established for free silica, asbestos, and other m a terials. For both silica and asbes tos, 5 million particles per cubic foot is considered as maximum w orking concentration. The U. S. Public Health Service has suggest ed a procedure by which the total dust concentration in millions of particles per cubic foot is m ulti plied by a percentage of free sili ca. If the resulting figure is more than 5 million particles per cubic foot, the condition is considered unsafe. If less than 5 million, the condition is considered safe. There should be considered certain limits of dustiness for any type of dust, whether it be merely a nuisance value or health consideration. To most industrial hygienists, 50 m il lion particles per cubic foot is the maximum atmospheric concentra tion of dust under which an em ployee should work. It should be pointed out that the only way of determining both the nature of the dust and the actual concentration is by direct sampling and similar procedures for the counting of dust. Case History MANY industries having prob lems of dust control recog nize the existence of such problems to varied degrees. Some take pass ive attitudes, while others apply s o u n d engineering procedures which result in a real job of dust control. Such modern engineering methods are used by the LeT ourneau Company of Toccoa, Georgia. This particular plant manufac tures heavy road grading equip ment and its major dust problem lies in operation of a foundry for the protection of basic steel parts. It is interesting to note that this Com pany considers the control of dust as a part of the general over all production schedule and as a result has its control methods inte grated into general plant opera tions. Although there are several methods which can be used for control of dust, ventilation, both in the form of general and local exhaust, probably offers the most satisfactory method and it is this approach which has been used by the LeTourneau Company. For general ventilation in the foundry, two 15-foot fans are installed which handle 500 thousand cubic feet per minute each. Actually, the material removed by these fans is m ade up principally of smoke rather than true dust. Two electric arc furnaces are operated and these are equipped with roof fans located immediately above the units. These fans handle BO thousand cubic feet per minute each. Again, the major portion of the material coming from the arc furnaces is smoke rather than true dust, and comes from the alloy and flux material charged into the furnaces. A problem of dust control in any foundry is the shakeout operation. This is particularly true where s h a k e o u t is mechanical and handled on a vibrating screen or grate. Here, a line conveyor sys tem is used to bring the castings directly to the shakeout grate. A canopy type hood is installed im mediately over the grate itself. In addition to canopy, side enclosures are provided which prevent air leakage. The fan serving this hood delivers 35 thousand cubic feet per minute, which results in a high capturing velocity at the entrance and discharge ports. An excellent job of dust control results on this particular operation. Sand conditioning in many foundries is a dusty job. With the LeTourneau Company this is handled by means of local exhaust ventilation and three bag type fil ters handling 6 thousand cubic feet per minute each. Tumbling opera tions for cast cleaning are also pro vided with local exhaust ventila- ( Continued on page 80) F I G . 6. L O C A L E X H A U S T ON T U M B L E R S F O R C A S T C L E A N I N G . F I G . 7. B A G H O U S E A ND S A N D B L A S T U N I T F O R C A S T C L E A N I N G . C ' u r o y Ix `T njrr.eau <'o. M SOUTHERN POWER & INDUSTRY for NOVEMBER, 1946 at least 75%. Figure 2 sho\ys the condition of the tube that jfailed. Other tubes were found eroded adjacent to U bolts holding baffle tiles. The U bolts provided suf ficient interruption in jias flow to cause eddy currents ap'd localized impingement. (Fig. 3.) Erosion by particles^ of fly ash - - ............. - f* - - - ................. i C a n d y M a k in g (Continued from pige 60) not be taken for granted, a chemi cal laboratory is essential. . The Brock Candy Company is now in the process of constructing a modern chemical laboratory and training a technician to perform control analyses. The laboratory, which is located in a large air con ditioned room near the candy' cooking operations, is equipped with modern stone-topped labora tory benches, the latest chemical glassware, and such special analyt ical instruments , . a s.; balances, vacuum oven, refractometer, and pH meter. Provision has been made for such analyses as moisture, in vert sugar, viscosity, pH, melting point, and refractive index. Many of the control tests have been de veloped specifically for the Brock Candy Company, and new pro cedures will be added from time to time as the need arises. The Industrial Research Institute of the University of Chattanooga has cooperated . with the Brock Candy Company in selecting the equipment, outlining and develop ing. analytical procedures, and training a technician to operate the control laboratory. A research and unburned fuel has also been found in stoker-fired boilers. At the time of each shutdown for cleaning and preventitive main tenance (at least once every four months), all areas vulnerable to erosive attack should be examined. Areas most susceptible are; . i 1. Where- flow of gases makes a \ turn, throwing out particles of 2. Behind any cracks, breaks, or y gaps, iri a gas baffle., 3( Adjacent to any! projection that might divert normal flow of gases. . Should the boiler be provided with an induced draft fan, observe the condition of the blading. Ab normal wear may be indicative of erosive attack in the boiler. Careful attention by all engi neers to the problem of erosion may well'prevent a serious acci dent. project on improvement of the quality of candy has been sponsor ed by the Brock Candy Company at the Industrial Research Institute of the University of Chattanooga. Since all raw materials will be analyzed and tested in the com pany laboratory, variation in prop erties will be detected before the material is used. This procedure will assure products of uniform quality, since inferior raw ma terials will be discarded and form ulations will be based on the ac tual analysis of high grade raw materials rather than on standard procedure which do not make al lowance for variation in the in gredients. Analysis and testing will assure high quality of finished products and permit any difference in quality to be detected. In this way, any unavoidable errors in manufacture can be corrected and adequate controls instituted to pre vent their reoccurrence. The facilities of the control lab oratory will also be available for the evaluation of research and de velopment work being carried out in the factory. In addition to main taining the production of uniform high quality products, the person nel and equipment of the control laboratory will be available for many other technical, assignments in the plant. The modernization program of the Brock Candy Company is tak ing place at a time when almost any product, regardless of quality or cost, can be sold. Tne real bot tlenecks today are shortages of raw materials and skilled personnel. However, progressive businessmen know that these conditions are only temporary and that within a few years, companies which can-; not guarantee quality will not be ablq to sell their products. The Brock Candy Company will con tinue to be a leader in its field be cause it has refused 'to sacrifice quality of its products in these days when consumer demands are greater than the supply of raw ma terials and because it has already inaugurated a program of control and research which will result in constant improvements. Dust (Continued from page 64) tion and dust arrestors as is shown in the photograph. Note that ex- haust is applied through the trunnion of the tumbler. In foundry operations or any other industrial type processing, housekeeping is an important fac tor influencing the generation of dust. This foundry employs two five horsepower vacuum cleaners for floor maintenance. By this pro cedure loose dust, sand, and the like, is removed from the floor and is not projected into the atmos phere by the movement of ma chinery, scuffing of feet, and the like. This is one impressive point in the operation of this particular foundry. Excellent housekeeping is combined with a good procedure for materials handled. In all of the attempts at dust con trol at the LeTourneau Company, employee cooperation is obtained. Employee c o o p e r a t i o n comes through planned program of em ployee education and employee participation in affairs involving the health of the worker. Periodic dust samples collected in the LeTourneau foundry indi cate atmospheric concentrations on various operations well below what is considered as maximum safe working limits. 80 SOUTHERN BOY/ER .4 INDUSTRY,for NOVEMBER, .1946