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Providing the high-pressuro water needed to break up the coke in the coke drum is this multistage centrifu gal pump, driven by an Elliott 1-1*0hp, single-valve, multistage turbino. TURBINES DRIVE HIGH-PRESSURE PUMPS SERVING DELAYED COKING UNITS by H. H. FORBES, Promt Bnglnw, 7ho Ohio Oil Compony, Robhwn, Winch Refineries lu recent years have beeu faced with an ever increasing demand for distillate fuels without a comparable increase in the demand for the heavy residual fuels. The Delayed Coking process which uses these residual fuels to produce coke, has therefore become an important refining step in the economic processing of the heavy asphaltic fuel stocks. At the Ohio Oil Company refinery in Robinson, Illinois, a low sulfur coke is produced from the heavy bottoms obtained during the distillation of crude oil. In the coking unit process the crude heavy bottoms are supplied with proheal and beat of reaction in a furnace and then enter a coke drum (16 ft in diameter by 85 ft high overall) where the coke is deposited. The materials remain ing after the coke deposition pass from the top of . tire coke drum to a fractionating tower where the gas, gasoline, and gas oil are separated and then direoted toward normal refinery handlingprocesses. Since the coking is a continuous process, two coke drums operating on a 24-hour cycle are re quired. When the cycle on an individual drum is completed, steam is introduced into the drum for removal of any light ends remaining in the coke, and then the coke bed is cooled with water. When the cooling oycle ie complete, the water is drained . . from the bed. The coke is removed hydraulically by the use of a cutting tool from which issues four highvelocity, high-impact water jets. To keep down the height of the derricks above the coke drums two-piece drill stems are used. The high-pressure (1500 psi) and high-volume (1100 gpm) water re quired for these jets is supplied to the cutting tools and nozzles by means of a multistage cen trifugal pump. This pump is driven by an Elliott 1480-hp, seven-stage, single-valve condensing tur bine using steam at 600 psig, 750F, with a flow of approximately 1200 lb per hour. Experience has shown that generally a steam turbine drive is moTe economicalthan a motor or any other prime mover for this intermittent service. At the start of the decoking cyde the water bypasses from the discharge baok. to the suction of the pump as the turbine is brought up to speed manually. When the decoking operator needs water, ho doses a solenoid valve In the pump bypass by means of a control at the top of the coke drums and when he wishes to stop decoking tem porarily he opens the valve. When drill bits and stems are changed, the solenoid valve is also opened. Thus, the pUmp and turbine operate at the same speed throughout the coking cyde. After drilling, the turbine is slowed down by hand until just turning oyer and continues at that speed until the next decoking operation is started. The coke out from the drum falls directly into rail hopper cars and is transported to storage or direotly to the consumer. Approximately 250 tons of coke (six hopper cars) are produced per day in the Ohio Oil unit. This coke is mado into eleotrodes whidi are used in the manufacture of aluminum through the electrolysis of bauxite. POWERFAX, SUMMER 1968 is rb*ft/T SC-ETM-2581 OTHER ELLIOTT EQUIPMENT INSTALLED AT OHIO OIL COMPANY REFINERY, ROBINSON, ILL, Left--This Elliott turbine-driven compressor serves a caialytio '.oraoklnt unit. The 3140-bp, eh-stage, multivalve turbine drives the 80,000-ofm compressor at 4700 rpm. I At right, above, it an ElKott 863-hp, 9666-rpm steam tur bine which h driving a compressor In the alkylation plant. The third Elliott 4000-kw turbine-generator unit was re cently added to the power plant at Robinson. All tbreo turbines are served by Elliott surface condensers. An artiol? in tbe Summer 1950 Powcrfca, covering tho orpension pro gram at Robinson, carried plotures of tbe Aret two turbinegenerator unite, a turbine-driven centrifugal compressor, steam jet ejeotors, and also pump-driving atenrn turbines. 14 POWSRFAX. BUMMJCR ISBB And here is an Elliott 1445-hp, 9280-rpm, multistage steam turbine which efficiently ddres the contrifugal compressor serving the catalytic reforming unit 31 i HERE'S ANOTHER TURBINE IN DELAYED OOKINQ SERVICE eOWERFAX, BUMMER 1968 Serving a Delayed CokiDg unit in Oklahoma is this Elliott 1633-lip, 4255-rpm single-valve, multistage turbine, driving a Paoiflo decoking pump, which, at rated conditions, delivers approximately 800 gpm of water at 2300 psig operating pressure. To remove the coke from the drum after it has been quenched, aholeis drilledvertically from top to bottom. A rotary drill head and drill stem, attached to die high-pressure water line, is then lowered through this hole to . the bottom level of the coke, and the pressure is applied. The drill stem is gradually raised manually by an operator at the top of the drum, who also controls water pressure by remote control of the turbine speed. J6 I l I -- '" I POWERFA* Summer 1954 Vol. 36 No. 2 Published by Elliott Compony since 1923. Distributed quorterly to more than 30.000 customers and friends in power plants ond industries using Elliott mechanical and electrical equipment. See back cover. Editor C. W. Kalbfus. Copyright 1954 Elliott Company, Jeannette, Pa. 1 FRONT COVER We've designed this issue's cover around the direct-current motor. The textured background pattern ts a photograph, some what enlarged, of a gloss-backed mica sheet, widely used in d-c insulation sys tems. Superimposed on this ts the electrical symbol for a d-c motor. And the photo graph shows a group of d-c motors at Weirton Steel Company, subject of the feature article beginning on the opposite page. NEW PUBLICATION Bulletin P-10. Power Recovery Equip ment for Chemical Processes, 16 pages. Announcing a new line of high-tempera ture gas turbine compressors, designed to form an integral part of a chemical process. Now installed in several nitric acid plants, this equipment has made possible substan tial savings in process power cost. See page 18 of this issue for a review of the operation and application of this equipment. Summer 1958 WEIRTON-S HIGH-SPEED CONTINUOUS ANNEALING LINE 3 THEY PUMP CEMENT (Marquette Cement Manufacturing Co.) ELECTRIC TUBE EXPANDING CONTnO- SPEEDS EVAPORATOR REPAIR JOBS NEW PIPELINE TAPS RICH CANADIAN CAS FIELDS (Wwumwt Traomxmion Co.. Ltd.) 12 TURBINES DRIVE HIGH-PRESSURE PUMPS SERVING DELAYED COKING UNITS (Ohio Oil Co. aud Oklahoma installation*) 13 ELLIOTT 12.000-HP. 3600-RPM SYNCHRONOUS MOTOR DRIVES COMPRESSORS AIRCRAFT GAS TURBINE LABORATORY (Fairchild Eoffioe nod Airplane Covp.) U POWER RECOVERY G.AS TURBINES REDUCE CHEMICAL PROCESS POWER COSTS COLORADO RIVER AQUEDUCT--ONE OF SEVEN WONDERS 21 THE NEW RIDGWAY ACOUSTICAL LABORATORY 22 SEVEN YEARS AND 90 RPM APART (Dieael Generator*) 26 TOPPING TURBINE SERVES STEEL MILL MODERNIZATION 27 "LOX" SERVES MISSILE EFFORT (Santa Susan*. Calif.) 2S POWERCRAX 31 MCLAUGHLIN, VICE-PRESIOENT Wayne McLaughlin has been appointed vice-president, engineering. Mr. McLaugh lin started with Elliott Company in 1934 as a turbine engineer. He contributed an article on turbine governors in the Autumn 1940 Powerful. He switched to the com pressor engineering department In 1943 he went with Carrier Corporation as di rector of development for heavy compressor equipment. Later he was in charge of the industrial machinery department of the machinery and systems division. He then became assistant to the president. When Elliott became a division of Carrier Cor poration. Mr. McLaughlin became liaison man between Carrier ond Elliott. E. F. Downey, has been appointed Q lotte district manager. A graduate of Nc Carolina State University in electrical a neering, he came with Elliott Compan; June, 1952, after four years service in Navy. After completing his appren course, he was assigned to the Crod Wheeler application engineering depi ment. In October 1934, he went to Charlotte district oflice as field engin M. A. KING Marcello A. King, on Elliott Company vice-president, died March 20. 1938. in the West Penn Hos pital in Pittsburgh, aged 65. He never completely recovered from an attuck suf fered in October. He started with the Kerr Turbine Gxnpuny in 1916, which was taken over by Elliott Company in 1921. He was chief engineer of Kerr Turbine (Company, became chief turbine engineer Tor Elliott Company, aud in 19.32 manager or the turbine department. In 1941, be be come manager of engineering, and in 1948 vice-president in charge of engineering. W. McLaughlin A. P. Grimm DISTRICT OFFICES A. P. Grimm is now rnunager of the xMilwaukec district oflice. A native of Al toona, Pa., he is an electrical engineering graduate of the University of Pittsburgh. .\rtcr considerable industrial ex|crience and five years in the army from which he emerged us a first licutenunt, he joined Elliott Company in June, 1951, as field engineer in the Philadelphia oflice. He was assigned to the Wilmington sub-district office in 1932, where he remained until now. E. F. Downay W, J. Lyorta W. J. Lyons is now manager of Newark district office. Although de noted "Newark", the oflice is actually Bloomfield. N. J. Mr. Lyons (who ser his country in the Marines und in the N for three years during the war, emerj us u second lieutenant) joined Crocl Wheeler in August 1948. He saw servic the Philadelphia and Washington ofli Since Muy 1954, lie bus been manage the Charlotte district ollice. Lee A. Wells, formerly in Milwaukee now manager of industrial motor sole tins Chicago urea. Recent assignments from the Grad* Student Program: Allison Roesch to Dalhis office; Donald BrLsbune to the I adelphia office; John Radack from Oocker-Wlieder plant to the Detroit of 3 WEIRTON'S HIGH-SPEED CONTINUOUS ANNEALING LINE POWENFAX. SUMMER 19SS WeirIon Steel Company's new continuous churning and annealing line is 560 ft long, bundles 60.000-lb coils of coldrolled strip steel up to 45 in. wide. Electrical equipment for operating and control was furnished by Elliott Company. The iiuce sthuctuhe shown here represents a giant step forward in the art of producing tin plate. It combines two operations into one-- cleaning and annealing--and it operates at a record strip speed of 2000 ft per min. Furthermore, this new line eliminates the former need to process strip in three separate degrees of temper, since it imparts a universal temper suitable for all end products. This modern line first went into operation in August of last year at the Weirton, West 3 1 PAY-OFF RErlS WELDER ENTRV Dunk ENTRY scrubber ELECTROLYTIC TANK DElfVfRY SCRUBBER SIMPLIFIED SKETCH SHOWING THE MAJOR ELEMENTS OF WEIRTON STEEL'S CONTINUOUS ANNEALING LINE. l) 111'i A view of Ihe entry end of tint line, slutwint; the two pay-ofT reels. Knelt rHl is IKtwertNj by tin Klltnll 150 kw. 2(MI/]*IM-rprn. 230-volt d-etirajf geiieralor. linntetlinlcly following U reels is Urn welder vvbieli ijuickly welds tin* len<l etlp* of a waiLinK<*oil to Mh'cimI of ( lie coil mov ing tlirmijrli the line. Virginia, plant of Weirton Steel Company, a divi sion of .National Steel Corporation. It is a city bliK-k in length and towers ns high as an eightstory building. Its capacity, at top operating speed, is 60 tons of tin plate per hour. Weirton"s new annealing line is the culmination of more than a quarter-century of development. In 1932. one of the first experimental (pilot) con tinuous annealing lilies was installed. Since then, designers and electrical engineers have devoted themselves to the solution of tlie multitude of problems involved in successful high-speed con tinuous annealing. Weirlon's new line represents close engineering eoopenition between Weirton Steel and Elliott Company. All electrical e meat--generators, driving motors, and cont was supplied by Elliott. In simplest terms, the line does its wor 30-ton coils of cold rolled strip. The stri received from the cold mill, is hard, some brittle, and unsuitable for most types of fal tion. After cleaning the strip, the amiealiiq passes it through gns- and electrically-heatet tioiis of the furnace. Here, the strip is raisci carefully regulated temperature, then gruc reduced to atmospheric temperature. This p tempering relieves internal strains entiled i steel when it was rolled, and imparts a deg softness and ductility which make it workul further processing. The line is divided into three parts, an section, an uunrulintj section, anil a Jelirrry sc Coils are fed into tlie entry cud or the li welding the lead edge of a wailing coil to tl of the coil moving through the line. The slri| pomes through a series of cleaning proces dried, and enters the first looping lowe simplified sketch above) prior to enteriu furnace section. This tower, made up of fourteen 50-ft l provides a strip storage capacity of TOO ft. ' necvssarv to provide sufTicieut looping or si lids [mint to permit welding of coils at the end without stopping the strip passing llirou furnm-e. Sketch shows lower in il.s `Tull' pc The I'urmice has a radiant lube, gas-lirod h section. rollout! by tin electrically-heated holding zone. Then follows a slow cool zone, fast cool zone, water quencher, and air dryer. From the furimtx* section, the annealed strip passes into a second looping tower, shown in the sketch in its nearly empty position. Identical with the first tower, this provides sufficient slack at the exit for alternately changing the two w inding reels. Tims, the line can continue to operate without stopping in the furnace while finished coils are lining removed. A special doublc-eut shear and pusher pinch roll at the delivery end cuts the strip and transfers it from a full to an empty reel at strip speeds up to add fpm. After leaving the line, the cleaned and annealed coils are moved to the nearby tin mill building where they are first "skirl rolled" to impart a good surface, then electroly tically tin-plated. The Weirton line is designed to process coils up to 15 in?widc. and in strip thickness from .0075 in. to .015 in. Actually, strip as thin as .0015 in. has been successfully annealed. Obviously, it re quires extremely complex and prrs ise coordination of the various electrical drives In handle such thin gages of material--at speeds up to 2000 fpm-- without damage or interruption. The entry seel ion of the line is powered by a 250-kw. 275-volt d-egenerator. A geueralor moloropemted field rheostat provides uniform accelera tion and deceleration at any desired rate, and a photoelectric control maintains speed relationship between sections to insure the looping lower being Delivery end of* the line, showing tile two winding reels which receive the. tinneuled strip. When one reel is full, the strip is cut hy a spread double u|*-eiil shear. The strip is then transferred to un empty roll, ell at .-pnsJs up to .IM) fpm. full. Line speed will not exe<*ed-2000 fpm during normal operation of tills section with the looping tower full. After a slow-down period for welding, the generator voltage may be mised to 273 volts with a <s>rresponding increase in speed to 2100 fpin. Strip is fed into the line from either of two mandrel-type payoff reels powered by 150-kw, 200/1200-rpin, 230-voll rl-c drug generators which serve us generators as soon us tension is estab lished. Between the pay-oir reels and the No. I bridle are 18 helper roll drives. These motors are I ROWERFAX. SUMMER 19SS s One of the live bridle roll* which convey the strip from one section to another (see the sketch, pages 4 and 5). compound wound with characteristics to insure load-sharing stability. The No. 1 bridle is the "keynoter" for the entry end section. The top roll of this bridle is driven by a 50-lip motor and the bottom roll by a 150-hp motor. Special cross-connected series fields insure that load division between these motors is propor tioned to their ratings. A deviation from this ratio may be obtained if desired by adjustment of their shunt field vernier rheostats. This system provides positive load division regardless of the rapidity of the load changes, and unfailing reliability. The annealing section of the line is run at constant speed except for slow-downs during weld ing. The strip enters this section from No. 2 bridle which lias a lop roll powered by a 30-lip motor a bottom roll driven by a 23-hp motor. These mol have the same provision for load division as No. I bridle roll drive. There is a single loop tween Nos. 2 and 3 bridle rolls. No. 3 bridle r are powered by two 19-kw drag generators. ' booster field is regulated by a photo thyrot modulated loop control to maintain position of f hanging loop between Nos. 2 and 3 bridle r The thirteen 5-hp and forty 3-hp annealing nace roll drives convey the strip through furnace and precede the No. 4 bridle rolls. T roll drives have trimmer rheostats and amrrn for their control, and serve as the "keynoter' the annealing section. An air-operated tern meter controls the tension between the fumact No. 4 bridle. A 38-kw drag generator is conn* to the top roll of No. 4 bridle and the botton drives a 19-kw drag generator. _ All motors in the annealing section are pov by a 250-kw, 275-volt generator with separ excited field controlled by a motor-operated erator field rheostat with control switch oi master desk. The position of this rheostat t mines the line speed. The strip enters No. 2 looping tower from bridle and is pulled out of the tower by bridle rolls. No. 6 bridle rolls and the two wi reels are driven by the 250-kw, 275-volt gen for the delivery end section of the line. Some of the thirteen .Vhp ami forty 3-hp motors that power the unneaiing furnace roll drives which convey the strip through the furnace. 6 flm four-unit KUiolt motor-generator set supplies (itwcr for IIk; entire annealing linn. t ^synchronous motor. ruled 1000 lip, drives jjirec identical 250-kw, 275-volt, d-c gener ators which supply the entry section, the jimuulingsection, and the delivery section. j i)ver-aU view of the annealing line from ! the delivery end. Approximately 200 El liott motors and generators are required for powering this huge processing line. T ! bridle has a 38-hw drag generator driving top rolls, j and a 56-kw drag generator for bottom rolls. I The speed of the delivery end section is matched I to the annealing section through a motor-operated i rheostat for acceleration, and a photoelectric con ' trol to insure the looping tower being empty. Each winding reel is driven by a 200-hp. 200 1200-rpm motor and is controlled by a rotating-typexurrent regulator for tension control. The pusher pinch rolls arc driven by a 75-hp motor and arc synchronized with the strip speed. They en gage the strip before the cut and arc in contact until the strip is wrapped on the empty reel. All visitors to the Weirton installation are im pressed by the annealing building which Is de signed to contain two additional continuous an nealing line's. The operating door is at the same elevation ns the original tin mill department. With this inetlnsl of construction, the required looping towers before and after the annealing furnace were placed downward Ihrough the building rather than elevated as in designs where the operating floor is at grade. POWERFAX SUMMER IS3S Tltt! complex control system wua designed by our Industry Engineering Department in cooperation with Weirton Steel Company engineers. Photograph at Memphis dock slams four of the latest type self-unloading cement barges, capacity 8200 Ixarrels THEY PUMP CEMENT M arqI'GTtk Cement Manueactehinc pant lias grown from very small beg'umii 1880 to one of the notion's leading ceineu' dueers. The original plant produced less tlia carload of cement a day. Now the company network of plants, terminals and sales offic _ tending throughout the mid-continent urea duction totals some I6.300.0IHI barrels selli $4.1,000,000 annually. Marquette moves some of its cement ti on tlin Mississippi River from Cape (lirord Memphis and St. Louis with n lleet of twr liouLs and 25 barges. The barges, rangin* small 800-ton-eapacily units to modern 15 carriers complete ilit steel covers and liigl unloading pumps, have n combined rnpn A closefip oPatoruge xilim at Memphis. POWERFAX. *UMMI The view below shows storage silos and dock bridges at St. Louis. about 25,(100 tons. The licet includes 10 coal barges and four cement carriers, dual-purpose craft capable of handling grain cargoes also. .Marquette's newest producing plants, tin* wet process plant at Cape Girardeau and that at Miluaukeo.'Vith of which began producing early in 1957, were conceived and built with the im portance of water transportation in mind. Dry cement Ls speedily pumped by the Fullor-kinyon system into and out of barges. The Cape Girardeau facility includes large waterside storage silos for liuislied cement products. From these silts tin* product is pumped into surge tanks at the river dock, is then loaded into barges, and moved to St. l-ouis or Memphis shipping terminals. Tito handling of dry cement by pumps, (some of which are driven by Kllintl C-VV motors, us shown i by our picture), although a usual procedure in the industry, seems an interesting footnote of progress. Dry cement is pumped from barge to silos by KullcrKinyon pumps located under the cement hopper, and driven by Elliott C-VV 125-bp. 1200-rpm induction motors. POWEftFAX. SUMMER 19S0 t ELECTRIC TUBE EXPANDING CONTROL SPEEDS EVAPORATOR REPAIR JOBS Two years ago Manistee Engineering Asso ciates, evaporation consultants of Manistee, Michigan, were called upon to furnish tube sheet replacements and other repairs for Manistee stilt evaporators built some years before by the Manistee Iron Works Com pany, which had pioneered iu the building of equipment for the evaporation of salt and similar chemicals. Most of this equipment is still in service at the plants of the leading salt producers of this country and Canada where the larger units are producing 300 to TOO tons of salt per day. These units were built to withstand corrosion, erosion, and the ravages of time. Occasionally, after 20 years or more of service, it has been necessary to make tube and tube sheet replacements iu some units, usually in the first effects. Earlier lube sheet replacements were made in this manner. The replacement parts were duplicates of the parts used in the original installation. .New methods of design have eliminated the necessity fir the copper expansion joints and welding with special apparatus lias been xulislitulrd for the riveting. In the past, replacements of this sort were made using the same materials as were used when the units were built. A change iu ownership of the original builder however, made new replacement procedures necessary since all patterns for cast iron evaporating equipment hud been scrapped when its man ufacture was discontinued. Because of this situation Donald C. Bay and W. Arthur Tobey, partners who organized Manistee Engi neering Associates, were asked to furnish suitable replacements for worn-out parts using up-to-date materials and modern construction procedures. After considerable study and investigation, it was decided that (90-10) cupro-nickel plate of a thickness of not less than Vg in. would satisfy all the requirements as a suitable replacement for the cast iron tube sheets. The selection of this metal was based on the characteristics of the alloy and other factors. The metal could be machined and drilled easily; by using recently developed welding techniques it could be weklcd as easily as steel; it was corrosion-resistant in brine and similar chemicals. Furthermore, tube-expanding skills and equipment had been perfected enabling mechanics to roll lubes of No. 16 gage copper or cupro-nickel in tube sheet plates as thin as 5 J iu. without the slightest danger of damage to the tube or lube sheets by over-expanding. This factor was the source of much concern until it was discovered that the problem could be easily solved by the use of the Elliott electric control lor tube expunc The purchase of complete Elliott tube ro equipment was made with the understanding the equipment was to be accepted only aft demonstration by a field engineer proved that machine performed as specified. This demon: tion was given in a 12-ft diameter Manx: evaporator at an Akron salt plant when the tubes were being placed in the steam chest sec In a few minutes the equipment was accepted officially became the property of Manistee ueering Associates, for this electrically contn tube expander rolled the tubes in these thin si quickly and uniformly. Once the dial of the coi was set for the desired tube expansion no fui adjustments were necessary throughout the rolling operation for the bottom as well as the ends of the vertical tubes. When the tubes were tested for leakage, the "leakers'' were found to be those missed ent by the tube rolling team. To date this Elliott ciskm tube rolling equipment has been use salt company plants at Akron, Ohio, Wal Glen, New York, and Port Huron, Michi With this machine nearly 10,000 tubes have properly rolled into *$-in. thick cupro-nickel sheets without damage either to the tube en< to the tube sheets. It is possible to roll 200 tc tube ends per hour without much effort on part of the operators. The machine is depend and fast. it was gratifying to those responsible for replacement work that this phase of the job c be done so well in so short a time. Compared t< rugged tube rolling processes of the past, I new techniques are truly of the "atomic" agt We asked about the wire screening shown oi evaporator walls in several of the pictures. W informed that this is put on as a reinforcemen the salt scale which forms on the sidewalls a; evaporator is operated. This wire holds the scale in place until the clean-out or boil-out p is over, when the scale is removed by fillinf evaporator bodies with water and boiling. I falling off during normal operation of evapon gives the operators trouble not only by hind the evaporating process, but it is likely to plu lines handling the continuous removal of tin slurry. 10 POWCRFAX. SUM M KR \bove left, an operator is shown rolling tubes in a replace ment job the way they used to do it. To roll 2500 2^ in. copper tubes by hand in this 25-fl diameter evaporator sually took four men on a three-shift schedule about a week to do a "quick" job. The extension bundle for the toller was a great help for rolling on top, but rolling the bottom end of the tubes was a tiresome, spine-twisting job. Picture above right shows the 2|4-in. copper tubes which ire being rolled into a M-in. thick cupro-nickcl tube sheet ising the Elliott control, as shown in the large picture on : this page. Pictures show field welding procedures in mak| ing tube sheet replacements. The welds connecting two of three tube sheet segments and also the weld connecting ' the down take cylinder to the upper tube sheet are shown. In the large picture the electric control box was opened and ^tilted for photographing. It ordinarily stands flat with the lid closed for protection. The Elliott control takes all guess work from the tube expanding operation. The large dial nob controls exactly the amount of torque to be exerted i>y the electric motor which is driving tiie lube expander. Last summer Westcoast Transmission Company Limited completed its 650mile pipeline linking the rich Peace River natural gas This exterior view of Westcoast Transmission Company's compressor station > located at Taylor, B. C., shows the outside exhausts of the six gas engine comprt* Fields in Northeastern British Columbia to market areas NEW PIPELINE TAPS RICH in Southern British Colum bia and Northwestern United CANADIAN GAS FIELDS States. The pipeline runs from Taylor, on the Peace River, southward to the Canadian-United States border near the towns of Huntington, B. C., and Sumo, Washington, where At compressor station No. 1, located at Ti the gas is started on its journey southward 1 Ingersoll-Rand 2000-hp gas-engine compn it joins a line of the Pacific Northwest Pipeline Corporation running from the San Juan Basin in each equipped with two Elliott turbocha which will handle peak loads of 660 million New Mexico. At present the Westcoast line is delivering 400 million cubic feet of gas per day; feet of gas per day. Before the gas passes th the compressor station it is processed to n however, when additional compressor stations are hydrogen sulphide and liquid hydrocarbon! added to the line its capacity will be raised to 660 as propane and butane which are prevail million cubic feet per day. For the initial operation British Columbia gas. The processing and n of the pipeline four compressor stations were con of these by-products has become the rt structed. Four additional stations are planned. largest industry. Six Ingersoll-llanil 20U0-Up gus engine compressors, each equipped with two Elliott turbochargers start the gas on its 650-mile journey southward from Taylor. Arrow points to turbocharger ia foreground. 12 1 I ii |I <> I- Providing the higli-prcssurc water needed to break up the coke in the coke drum is this multistage centrifu gal pump, driven by an Elliott 1180hp. single-valve, multistage turbine. TURBINES DRIVE HIGH-PRESSURE PUMPS SERVING DELAYED COKING UNITS by H. H. FORBES, Rrocoss Engineer, Th Ohio Oil Company, Robinson, Illinois Refineries in recent years have been faced with an ever increasing demand for distillate fuels without a comparable increase in the demand for the heavy residual fuels. The Delayed Coking process which uses these residual fuels to produce coke, has therefore become an important refining step in the economic processing of the heavy asphaltic fuel stocks. At the Ohio Oil Company refinery in Robinson, Illinois, a low sulfur coke is produced from the heavy bottoms obtained during the distillation of crude oil. In the coking unit process the crude heavy bottoms are supplied with preheat and heat :of reaction in a furnace and then enter a coke ;jdrum (16 ft in diameter by 85 ft high overall) jwhere the coke is deposited. The materials remain^ dng after the coke deposition pass from the top of [the coke drum to a fractionating tower where the gas, gasoline, and gas oil are separated and then [directed toward normal refinery handling processes. _ Since the coking is a continuous process, two jeoke drums operating on a 24-hour cycle are re quired. When the cycle on an individual drum is .completed, steam is introduced into the drum for 'removal of any light ends remaining in the coke, and then the coke bed is cooled with water. When Ifthe cooling cycle is complete, the water is drained ;from the bed. .'.`The coke is removed hydraulically by the use if a cutting tool from which issues four high- locity, high-impact water jets. To keep down height of the derricks above the coke'drums two-piece drill steins are used. The high-pressure (1500 psi) and high-volume (1100 gpm) water re quired for these jets is supplied to the cutting tools and nozzles by means of a multistage cen trifugal pump. This pump is driven by an Elliott 1480-hp, seven-stage, single-valve condensing tur bine using steam at 600 psig, 750F, with a (low of approximately 1200 lb per hour. Experience has shown that generally a steam turbine drive is more economical than a motor or any other prime mover for this intermittent service. At the start of the decoking cycle the water bypasses from the discharge back to the suction of the pump as the turbine is brought up to speed manually. When the decoking operator needs water, he closes a solenoid valve in the pump bypass by means of a control at the top of the coke drums and when he wishes to stop decoking tem porarily he opens the valve. W'hen drill bits and stems are changed, the solenoid valve is also opened. Thus, the pump and turbine operate at the same speed throughout the coking cycle. After drilling, the turbine is slowed down by hand until just turning over and continues at that speed until the next decoking operation is started. The coke cut from the drum falls directly into rail hopper cars and is transported to storage or directly to the consumer. Approximately 250 tons of coke (six hopper cars) are produced per day in the Ohio Oil unit. This coke is made into elec trodes which are used in the manufacture of aluminum through the electrolysis of bauxite. CRFAX. SUMMER 13 OTHER ELLIOTT EQUIPMENT INSTALLED AT OHIO OIL COMPANY REFINERY, ROBINSON, ILL. Left--Thi Elliott turbine-driven compressor serves a caj lytic cracking unit. Tlse 3140-hp, six-stage, multivalva turbine drives the 30,000-cfm compressor at 4700 rpij At right, above, fc an Elliott 863-hp, 9535-rpm steam tur bine which is driving a compressor in the alkylation plant The third Elliott 4000-kw turbine-generator unit cently added to the power plant at Robinson. All turbines are served by Elliott surface condensers- An in the Summer 1950 Power/ax, covering the gram at Robinson, carried pictures of the first two generator units, a turbine-driven centrifugal steam jet ejectors, and also pump-driving steam 14 And here is an Elliott 1445-hp, 9250-rpm, multistage steam turbine which efficiently drives the centrifugal compressor serving the catalytic reforming unit. HERE'S ANOTHER TURBINE IN DELAYED COKING SERVICE Serving a Delayed Coking unit in Oklahoma is this Elliott 1633-lip, 4255-rpm single-valve, multistage turbine, driving a Pacific decoking pump, which, at rated conditions, delivers approximately 800 gpm of water at 2300 psig operating pressure. To remove the coke from the drum after it has been quenched, a hole is drilled vertically from top to bottom. A rotary drill head and drill stein, attached to the high-pressure water line, is then lowered through this hole to the bottom level of the coke, and the pressure is applied. The drill stem is gradually raised manually by an operator at the top of the drum, who also controls water pressure by remote control of the turbine speed. w*' ELLIOTT 12,000-HP, 3600-RPM SYNCHRONOUS MOTOR DRIVES COMPRESSORS IN AIRCRAFT GAS TURBINE LABORATOR The Fairchild Eocene Division of the Fair child Engine and Airplane Corporation main tains, as part of its plant installation on a 200-acre site at Deer Park, Long Island, a very line advanced gas turbine research laboratory. This facility serves as a testing site for small aircraft and missile jet engines and their com ponents under development for military and commercial applications. The laboratory has been carefully designed with a view to serving Fairchild's future needs adequately without ex cessive expenditure of funds. At the same time the laboratory contaius the most modern equip ment and instrumentation to permit use of modern techniques in simulated testing programs. Here an Elliott 12,000-hp, 3600-rpm syn chronous motor drives two centrifugal com pressors with a combined output of 120,000 cfm. These supply a continuous movement of air through test cell facilities for testing complete jet engines, turbine, compressor, combustion chamber, and afterburner components. Simu lated flight in an altitude chamber is accom plished and a supersonic wind tunnel made available for combustion research. It was apparent that the starting of this large motor could not be accomplished in the usual maimer because of the high inrush which is characteristic of two-pole synchronous motors. Also the power supply in the immediate area was somewhat limited in capacity. It was de cided to utilize a 1250-hp "cranking" motor which would be capable of bringing the 12,000hp synchronous motor and compressor assem bly up to speed. The large motor could then be synchronized to the line much as an a-c gen erator is in a steam plant. The 1800-rpm woundrotor motor, designed after consultation with tlie compressor manufacturer, has brought up to speed in a satisfactory manner the large motor and compressors. Elliott engineered the entire motor drive and furnished the electrical "package" including motors, gear, transformers, primary switch gear, starting and synchronizing control, and regulators. At the request of Fairchild the cranking motor and its controls were designed so that it could carry a 15 percent overload capacity when required and divide the load with the two-pole synchronous motor. With the latter also designed to carry 115 percent load continu ously, the total available horsepower for this drive is in excess of 15,000 hp. Two of the test cells at the Fairchild gas tur bine laboratory contain test facilities where high-speed compressors can be tested. Each stand is powered by an Elliott wound-rotor motor. In one instance, requirements dictated the use of a 6000-hp, 900-rpra (syn.) woundrotor induction motor. In the other instance, a 1250-hp, 1800-rpm (syn.) motor was found suit able. Each motor is connected to a speedincreasing gear which thus permits the equip ment under test to be operated at speeds as high as 20,000 rpm. By means of liquid rheostats and speed regu lators, the motore can be operated over a wide range of speeds, to accommodate the test pro gram at Fairchild. Flexibility of the Elliott designed control equipment has permitted Fairchild to achieve highly productive test time per actual hour of operation. No test has ever been interrupted or delayed by a malfunction of this installation. This schematic diagram illustrates the arrangement of the two compres sors, the two motors, and the gear. 16 POWUtFAX. iumh Aerial view of Fairchild Engine Divi sion, Fairchild Engine and Airplane Corporation, Deer Park. Long Island, New York. The gas turbine develop ment laboratory building is seen at left. This photograph shows the Elliott 12,000-bp, 3600-rpm, 13,200-volt synchronous motor designed to carry 113 percent rated load for two hours. The motor is started and brought up to synchronizing speed by the 1250-hp, 1700-rpm wound-rotor induction motor at the right. This motor is connected to the synchronous motor through a speed-increasing gear with a ratio of 2.24 to 1. It is perhaps unfortunate that the angle of this picture was such that the 1250-hp wound-rotor induction motor appears to be as large or larger than the 12,000-hp. 3600-rpm synchronous motor. Compressors are in background, switchgear on lower floor. Over-all view of a Southern nitric acid plant employing Elliott power recovery equipment. Capacity of the plant is 80.000 tons per year. The high-temperature process gn turbine develops 4960 hp from ex pansion of heated waste gases. A steam turbine, rated at 1320 hp, provides the required "make up" power for air compression. A new type of gas turbine, designed to form an integral part of a chemical process, has been developed by Elliott Company daring the past three years. Substantial power savings are being demonstrated by several of these machines now in service. POWER RECOVERY GAS TURBINE By j. a. tuttle Product e,,tin~riog o.pt, ciiion Company jnnneH* Po any chemical processes require a supply of air under M pressure in order to operate. The waste gas from a process of this type is frequently available at substantial pressure and therefore can supply power when expanded through a turbine. A new series of process gas turbine-compressors has been developed to make use of this power. The turbine is designed to expand the waste process gases at temperatures up to 1250 F. The compressor, driven by the turbine, delivers air to the process at pressures from 30 to 200 psig, depending on the number of compressor stages. Substantial savings in the power cost of compression can be achieved with such power recovery equipment. The manufacture of nitric acid through the catalytic oxidation of ammonia with air under pressure ofTers a particularly good example. In this process, the catalytic reaction produces a temperature of approximately 1600-1700 F in the gas stream. These gases are then cooled and the nitric oxide is absorbed in water to produce nitric acid. The gases can then be reheated by the high-temperature gases within the process. Low-temperature power recovery equipment (primarily reciprocating) utilizing these reheated gases has been in service for years. The new Elliott process gas turbine, however, is capable of handling gases at temperatures up to 1250 F. Compared with low-temperature power recovery, the power cost per ton of acid can be virtually cut in half with Elliott equipment. Table 1 on page 20 dramatizes the savings possible through higli-tcmperature power recovery. Assuming a power cost of one cent per kwh and a 200-ton-per-day plant, Elliott equipment will permit a saving of more than $100,000 per year, compared with low-temperature (400 F) power recovery equipment. High-temperature power recovery has a secondary advantage 18 ELUO; ^ GAS TURBO , COMPRESSC , u Installed ,,> - `-::atypl. nitric acid pia Elliott power recovery equipment in a nitric acid I plant. An Elliott steam tur i bine provides make-up pow i er to the PM-TC process gas turbine-compressor. Reduce Chemical Process Power Costs This illustrate!! typical power recovery equipment tor nitric acid plant service. Two-stage HM compressor, at left, delivers air to intercooler, thence to TC gas turbine compressor, right. Pressurised air then goes to the process. TABLE I Net air compression costs per ton of nitric acid. Assuming power at one cent per kwh. Net Power Cost per Ton No power recovery Power recovery at 400 F Power recovery at 900 F Power recovery at 1250 F $5.00 3.15 2.10 1.35 % Power Recovery ` 0, 37 58 73 . The new TC process gas turbine-compressor. Two-stage compressor with high-strength inducer-type impellers is at the left. The high-temperature process gaa turbine, made entirely of corrosion-resistant metals, is seen at the right. for nitric acid plants located in areas where air pollution by contaminated exhaust gases is a problem. Catalytic combustion chambers are avail able that will burn hydrogen or methane in the waste gas (before power recovery turbine) and re move or modify undesirable gases before they are exhausted to atmosphere. However, these combus tion chambers produce a temperature rise of 400 to 800 F and are therefore suited only for installa tion in high-temperature power recovery systems. In the nitric acid process, even with hightemperature power recovery, the process gas tur bine cannot produce rll the power required for air compression. In the case of a new installation the "make-up" power required can be supplied by coupling a steam turbine or geared electric motor to the process gas turbine-compressor. Combina tions of this type ("make-up" driver plus power recovery turbine) are compact and efficient and have almost invariably been installed in new plants in recent years. Elliott equipment in this service now permits higher turbine temperature and there fore lower power cost. In the case of an existing plant, with existing air compressor capacity, "make-up" power re quired can be supplied to the cycle in the form of compressed air. In this case the total waste gas from the process drives the gas turbine and the com pressor delivers air to the process together with the plant air system. No additional shaft power is supplied to the prc :ess gas turbine-compressor.' This second type of machine provides an excep tionally economical installation where the capacity of an existing plant is to be increased. In one case, the capacity of an existing plant with low-temper- 1 ature power recovery was approximately doubled by tile installation of an Elliott high-temperature process gas turbine-compressor--and without in creasing the air capacity of the plant air systemThe air compression cost per ton of acid was reduced accordingly. The process gas turbinecompressor applied in this type of installation takes its simplest possible form. No auxiliary power is required and therefore its cost is as low t as possible. POWERPAX. UMMER Elliott is supplying the type TC gas turbinecompressor for process applications. For the pres sure ratios required in most nitric acid plants, this unit is coupled either to a single-stage (type PM) compressor or to a multi-stage (type HM) com pressor. In either ease the last two compressor stages, after intercooling, arc a part of the type TC process gas turbine-compressor. These machines can be supplied for compression (rom atmospheric pressure to discharge pressures from 30 to 200 psig with inlet volume flows from 1 000 to 30,000 cfm. The power recovery turbine can be sized to supply either part or all of the compressor power required. It is designed for a maximum inlet temperature of 1250 F and a maximum pressure, at present, of 150 psig. Elliott is at present the only manufacturer who can supply process gas turbines over tliis range of flow and power for 1250 F inlet temperature. Our operating experience shows that our present de signs can operate reliably at this temperature with a minimum of maintenance and therefore moke possible a maximum power recovery- The manufacture of nitric acid offers an imme diate application of tliis type of macliine since almost all new American plants have been pressur ized for many years. To date more than 20,000 hp of efficient high-teinperature power recovery ca pacity has been installed in this service by Elliott. This equipment will undoubtedly permit, in the future, the pressurization or supercharging of manyother chemical processes to increase yield or re duce capital costs where, without power recovery, air compression costs would be prohibitive. I COLORADO RIVER AQUEDUCT --one of seven wonders On Apbil 15, at the Huntington-Sheraton Hotel in Pasadena, California, the American Society of Civil Engineers officially awarded a plaque to the Metropolitan Water District of Southern California. The Colorado River Aqueduct, which will ultimately bring one billion gallons of water per day to thirsty Los Angeles and environs, had been selected as one of the seven modern civil engineering wonders of the United States. The photograph above shows this presentation. The gentlemen, drinking a toast of Colorado River water, are, left to right: Joseph Jensen, chairman, board of directors; Robert B. Diemer, general manager and chief engineer of the Metropolitan' Water District; and Louis R. Howson, president American Society of Civil Engineers. On this tremendous project, Elliott Company is furnishing eight 12,500-hp and eight 9000-hp vertical synchronous motors, more of the big pumping motors than furnished by any other manufacturer. Later on, we will have an article in Powerfax on this tremendous world-wonder project. One of the Elliott 12,500-bp, 450-rpm vertical synchronous motors for the Metropolitan Water District, on test at oar Ridgway plant, is shown at right. 21 : : By j M. E. TALAAT, Ph.D., E.E. Research ft Dmlopmmnt Enginmnr Effiott Company, Ridgwoy Plant Industrial progress over the past quarter cen tury has made it necessary to use larger and larger electric rotating machines, particularly in the high speed range. The primary function of such ma chines is to provide a prime mover for a particular drive as in the case of an electric motor, or to provide a source of electric power as in the case of the electric rotating generator. But these primary functions of electric rotating machines give rise to secondary undesirable by-products, such as the generation of heat and the radiation of noise. While the machine losses enuring heat may run in the tens or hundreds of kilowatts of power, one watt of acoustic power, if radiated by a machine, could mean a sound pressure level of about 110 db (referred to 0.0002 microbar) in a typical live or reverberant room (a room with hard floor, walls and ceiling). This could mean serious risk of loss of hearing if an operator is exposed to the noise eight hours a day, 50 weeks per year, for five years, not to mention the discomfort and inability to com municate by speech. A 7000-lb thrust turbo-jet engine has an acoustic power output of about 10,000 watts compared to the 0.10 watt radiated by a so-called noisy motor and compared to the Yoq^oQO WQlt ra^'ate^ by the average human voice at conversational level. The motor which is radiating 10,000 times the sound power output of a man's voice, is putting out in horsepower more than 10,000 limes a man's power*. *lt is ssiil that a man can exert 0.1 hp eight hours per day. But since we are in constant search for the opti mum, we would like a motor which would put ou in horsepower more than 10,000 times a man' power but with only 10 times the acoustic powei of a man's voice. * Man is gifted with the ability to theorize, bul he must conduct experiments to validate his theo ries. These experiments invariably require exten sive equipment, facilities and instruments and very often even a special environment. The sum of these we generally refer to as a laboratory. A manufacturer cannot stop at theorizing the development of a new product and the experi mental verification of his design predictions. He must assure himself that product performance continues to meet his customer's requirements. So, just as he is able to load a motor up to rated horsepower and measure its winding temperature rise and its electric performance, he also wants to be able to check its acoustic performance. .is The Ridgway Plant Acoustical Laboratory w planned with two main purposes in mind: (1) tojbe able to evaluate and check theories on the noise generated by large electric rotating machines,as part of a noise reduction program, and, (2), to be able to conduct routine commercial tests to check the noise performance of a machine. TP' Requirements of the .New Noise Test Code, A new test code for measuring the noise pe*r formance of electric rotating machines is nojr being written!. The Acoustical Laboratory Con 'S POWtRFAX. SUMMER 1SSS forms to the environmental conditions set forth in j)ie new cotie. . It is now generally believed that the best way to evaluate the noise performance of an electric rotat ing machine is by the measurement of the total acoustic power level radiated by the machine for tie over-all band as well as for each octave-band j an octave-band analyzer. The acoustic power level in db is equal to 10 times the logarithm to the lose 10 of tlie acoustic power in watt referred to jO-13 watt (reference 1) or 10-,s watt -- picowatt Reference 2). Also, to take into account the varia tion in the sound pressure level as a function of jirection, the terra "acoustic directivity factor" for the over-all band as well as for each octave|d of an octave-band analyzer, is also being jecommended. The acoustic directivity factor is lefined as "the ratio of the acoustic power radiated by a point source producing the observed sound pressure level in a specified direction to the total sower radiated by the actual source in free field" reference 3). Unfortunately there is no commercially avail able instrument for the direct measurement of acoustic power. The evaluation of the noise per formance in terms of power levels has to be made indirectly by using the existing sound pressure level meters and octave-band analyzers and in serting certain measured data into the formulas for the calculation of power levels and directivity factors. In order to be able to evaluate the power levels and directivity factors from pressure level meas urements, the latter must be made in a free field, or in a calibrated semi-reverberant field where the results can be reduced to their equivalent free field values. Directivity factors cannot be evaluated from measurements in reverberant fields. The evaluation of the acoustic power level of a machine for measurement of the sound pressure level in a free field is based on the approximation that in a free field, beyond the near radiation Geld, the intensity level is equal to the sound pressure level. This fact makes it possible to obtain the power level by integration of the intensity level over a hypothetical hemispherical surface sur rounding the machine. Hence the test procedure for obtaining the power levels and directivity factors for large elec tric rotating machines should consist mainly of measuring the over-all and octave-band pressure levels at a certain number of microphone positions arrayed uniformly on a hypothetical hemispherical (The author is chairman of the large machine writing group of the American InaUtute of Electrical Engineers rotating machinery committee group on noise evaluation. surface surrounding the machine beyond the near radiation field. If the measurement is made in a calibrated semi-reverberant field, the sound pres sure levels obtained must Grst be reduced to those that would be obtained under free field conditions. This latter step can be carried out when the acous tic calibration of the room is known. Thus, if Lp is the average equivalent free field sound pressure level (referred to 0.0002 microbar) measured on the hypothetical hemispherical sur face of radius r ft, then the souud power level Lw is given by Lw = Lp-|-20 log,# r+7.5 db referred to 1(H3 watt (Replace +7.5 by --2.3 if the refer- (1) ence power is taken --10-11 watt) Also the directivity factor in any specified direc tion toward a point which is given by the spherical coordinates (r, 8, 4) and at which the pressure level is Lp (r, 8, 4>) is given by Q (r, 8, *) - antilog,. Lp-(r' (2) Conformity of the Laboratory with the new Noiae Teat Code The Ridgway Plant Acoustical Laboratory was planned, taking all these factors into considera tion. Its internal dimensions are: length 50 ft. This 4500-hp. 3600-rpm in duction motor is being tested for noise level in the new Acoustical Laboratory at the Ridgway plant. It is # specially designed building which effectively exdude; exterior sounds and mini mixes interior noise reflection POWERFAX, SUMMER 1S58 23 TABLE I Measured Ambient Levels in Ridgway Acoustical Lab oratory. Frequency A Sand in CPS * Ambient Level referred to 0 0002 Microbar 23.9 ir 1B j 20- ; 20- | 10.000 75 75150 150- , 300- ; 600300 600 1200 12002400 24004800 i36.4 1 49.4 . 49,4 ! 29 4 i 20 4 15 4 16 4 17 4 16 9 i !i 1 , width 30 ft, and height 30 ft. It has acousticallytreated walls and ceiling and a hard floor. Since no cranes could be practically employed inside the laboratory to handle any large machine, a pit running lengthwise through the centerline of the room was necessary to allow a flat railroad car carrying a machine to enter the laboratory and stand with its surface practically flush with the floor level. The machine is mounted on the flatcar in such a manner as to stand in the center of the laboratory floor when the door is closed. Isolation mounts are usually used between the machine and the flat surface of the car in order to minimize the transmission of vibrations from the machine to the flat surface of the car which can act as an eflicient sound radiator. The gap between the c surface and the rest of the hard floor also helps prevent any transmission of vibration front t machine to the floor, walls and ceiling. The walls and ceiling of the laboratory cons of an outer shell and an inner shell separated b\ large air gap. The outer shell is made of paro having fairly high sound isolation quality (hi transmission loss in db) over most of the frequen bands of interest. The inner surface of the oul shell is acoustically treated with sound-absorbi material. So is the inner shell, consisting of met lath. The horizontal and vertical transverse gii ers which support the metal lath were also acoi tically treated with sound-absorption material Radius of Hypo- 'FREQUENCY BANDS IN CPS tlietical Hemisphere 20-10,000 75-150 150-300 Directivity Factor Q % Deviation From Qav 2.415 10.17 2.415 3 96 2 305 4 58 TABLE II Comparison of the Over-all or Octave-Band Directivity Factors in a Certain Speci fied Direction (viz. the direc tion of Qmu), Which Were Measured at the Hemispher ical Radii Beyond the Near Radiation Field (yiz. r = 8, 9.10,11*4,13 and 14*4 ft). Directivity Factor Q % Deviation From Qm r-IO* Directivity Factor Q % Deviation From Q,,, r-ll*4' Directivity Factor Q % Deviation From Q,, Directivity Factor Q % Deviation From Q,,, 2.255 2.87 2 332 6 29 2.155 -1.69 1.965 --10.35 2 530 8.91 2.335 0 52 2.335 0.52 2.125 --8.52 2.280 3 45 2.080 5 62 2.415 9 57 2.155 -2.22 f-14*4' Directivity Factor Q % Deviation From Q,,, 2.030 -7.38 2.200 -5.29 1.987 -9 85 Average Directivity Factor Qa>> 2.192 2.323 2 204 Average % Deviation From Qjm 6.46 4.62 5.88 300-600 3 260 5.84 600-1200 2.280 7 54 1200-2400 2400-4800 4800-10.C 2.055 2.305 I 985 4.47 5 29 1.12 3.260 5.84 2.445 15 33 1 963 -0 20 2.255 3.01 2.175 10 80 3 180 3.24 2.305 8.72 1 920 -2 39 2.200 0 51 1 815 --7.54 2 900 -5.84 2.175 2.59 2 940 -4 54 1.920 -9.43 2.940 --4.54 1.597 -24.65 3.08 2.12 4.97 11.38 1.963 --0 20 1.963 --0 20 1.940 --1.37 1.967 1.44 2.125 -2 92 1 897 -3.37 2.125 --2.92 1.897 -337 2.125 --2.92 2.010 -337 2.189 2.93 I 963 . uto rOWKRFAX. UMMI courage lateral acoustic wave motion in the air act* behind the metal lath. This wall and ceiling rangement was believed to yield such a high ran constant (l\ is greater than 20,000 sq ft) for rh of the octave-bands: 75 - 150. 150 - 300, i0 - 600. 600 - 1200,1200 - 2100, 2100 - 4800. and iOO - 10,000 cps, that the sound field inside the kwh can be called essentially free field. Yet it is mch more economical than the wedge type armgement used in auechoic rooms. The isolated cation of the laboratory made possible very low inbicnl octave-band noise levels with the use of elatively inexpensive outer sliell sound-isolation innels (Table I), making it unnecessary to correct or ambient levels in noise tests made on most arge electric rotating machines. fn order to evaluate the noise performance of his Acoustical Laboratory in a meaningful way to uoth the users and manufacturers of large electric otating machines, a typical machine was isolationnounted on the flatcar surface inside the labora:ory. The octave-band pressure levels were measjred at six different microphone positions uni formly arrayed on a hypothetical hemispherical surface surrounding the machine (reference 3), whose center coincided with the projection of the center of the machine on the flatcar surface. The machine used had a shell diameter of 3 ft and was 5 ft long. The radius of the hypothetical herni1 spherical surface surrounding the machine was taken so that the minimum distance from any major surface was 5 ft, i.e. 8 ft, as required by the , new AIEE noise test code now being written. The test procedure was repeated with the microphone positions uniformly arrayed on nine other hypo thetical hemispherical surfaces surrounding the machine and having the radii, 4, 5, 6, 7, 8, 10, ltj^, 13 and 14j^ ft. The over-all as well as the octave-band power levels were evaluated using . equation (1) for eacli hypothetical hemispherical surface used. ' It was argued that if free field conditions existed : inside the laboratory, then for alt the hypothetical hemispherical surfaces surrounding the machine beyond the near radiation field, the evaluated sound power levels using equation (1) for the over-all band, as well as for each octave-band, should be the same. A comparison of the power i levels evaluated using equation (1) for the 10 ; different hypothetical hemispherical surfaces for ; the over-all, as well as for each octave-band, is tabulated at right. This shows that beyond the near radiation field (r ^ 8 ft, but away from the walls) the maximum deviation of the power levels (evaluated over hypothetical hemispherical sur , faces with 14j^ ft \ r \ 8 ft) from their average power level is 0.5 db or less for the octave-bands: POWERFAX. SUMMER 1938 in II k. oK 00 DB II 2 k. 1 hs- 0 -1 CO DB > UJ DB 1 <r UJ 0 Q. -1 -2 DB RADIUS IN FEET OF HYPOTHETICAL HEMISPHERICAL SURFACE SURROUNDING THE MACHINE 4 5 6 7 8 9 10 11.5 13 14.5 <i*t '4 .. iNcMn k __ i n__ i > Hradiation--h FIELD 1 --) ` 3 n i ( > rj t <) 1* a> ------ < '--; i DB 2 --< 1 a0 Si -1 UJ -2 $ DB UJ DB '1 . NEAR , [--RADIATION--4 1 FIELD <1 4 socc 3 2 1 0 cQ -1 OB CE <t , t r' 'l '"t 4 ___ ! <i 5 . .. 1 1 >-150-300 o UJ DB 3 2 1 0 -l DB < D DB 1 $0 -1 DB ui > DB 1 0 -1 DB DB 1 0 -1 DB DB 1 0 -1 DB 1 ft - L 1 1 <> , NEAR , p--RADIATION--4 1 FIELD 1 ~t~ "T T f i f-"**------- ---------13--600-1200 1 < } < rr i} , i 1* u1 i i 1 1200-2400 < > <j lJ --i 5-- 1 * < i____: 2400-4800 t i i it <, < >i --2____ 1 i____ : * <1 J- 4800-10000 4 5 6 7 8 9 10 11.5 13 14.5 23 FREQUENCY BANDS IN CYCLES PER SECOND 75 - 150, 150 - 300, 300 - 600, 600 - 1200 and L200 - 2400 cps; is 0.7 db for the over-all band, as well as the octave-bands 2400 - 4800, and 4800 10,000 cps. This is an excellent performance when compared with the elaborate anechoic rooms which yield a standard deviation of 0.5 db. The results for the 20 - 75 cps octave-band show a maximum deviation from the average of 1.3 db which is very good for this low-frequency band. Most anechoic rooms have a cut-off frequency of 100 cps. An interesting result, shown by the chart on the preceding page, is that the evaluation of power level over a hypothetical hemispherical surface surrounding the machine in the near radiation field (4 ft ^ r Z 8 ft in the given example) can lead to a deviation of 3 to 4 db from the true and properly measured power levels. This result sup ports the recommendation made in the proposed AIEE noise test code that the radius r be such that a minimum distance of 5 ft be maintained between the major surfaces of the machine and any micro phone position lying over the hypothetical hemi spherical surface surrounding the machine. In Table II the over-all and octave-band direc tivity factors are presented. These directivity factors were evaluated by applying equation (2) to the sound pressure level measurements made over the hypothetical hemispherical surfaces sur rounding the machine beyond the near radiation field (vis. r = 8, 9, 10, 11)4, 13 and 1454 ft). For each frequency band the directivity factor in a certain specified direction (viz. that of highest Q) is given at each hypothetical hemispherical surface radius r. The average directivity factor for each frequency band and the percentage deviation of the directivity factor measured at each radius from that average, are also tabulated for compari son. In addition, the average percentage deviation for each frequency band is tabulated. Directivity factors for the octave-band 20 - 75 cps are excluded from the table because no consistent directional patterns of the machine used as the noise source were observed in that band. The results given in Table II show that in i 300 - 600 cps band, where the directivity factor highest, the percentage deviation of the directivil j factor at each radius from the average directivil factor of all radii ranges from 3.24 to 5.84 j with an average deviation of 4.97 percent. This a small percentage deviation and the result can 1 considered excellent. For the remaining freque bands the percentage average deviations from 1.44 percent for the 1200 - 2400 cps up to 11.38 percent for the 600 - 1200 cps ! Even in this latter band where the worst deviatioi in the directivity factor of 24.65 percent take 1 place at r - 1454 ft, the results can still be con * sidered very good, particularly when it is remem' bered that a 25 percent variation in the directiv factor can mean a deviation of only one db in I calculated sound-pressure level using that dir tivity factor. The results of the noise analysis tests made it the Ridgway Plant Acoustical Laboratory and reported here, indicate that the acoustic environ- I mental conditions in this laboratory essentially and practically satisfy the free-field conditions indoors. This means that formulas (1) and (2) can . | be used to evaluate the power levels and direc tivity factors from sound-pressure level measure ments over hypothetical hemispherical surfaces surrounding the machine beyond the near radia tion field, all without the need of any environ mental or room calibration corrections. if* On the basis of tests conducted to date, this tsh particularly outstanding achievement in that wo have obtained essentially the same results as in an equivalent anechoic room but at about 8 percent of tlie cost. i| References i (1) "Acoustics", L. L. Beranek (a book) McGraw Hitt. New York. 1954. (2) "Handbook of Noiae Control". C. M. Harris (a book) McGraw Hill, New vork, 1957. (3) "Handbook of Noise Measurement*', A. P. G. Peterson and L. L. Bera^yk, General Radio Co., Mas*., 1956- SEVEN YEARS AND 90 RPM APART uie are two Elliott generators driven by diesei Kengines in a Nebraska power station. The generator in the foreground, rated 1000 kw, 360 rpm, and using a direct-connected exciter, was installed in 1949. In the background, is an Elliott 2141-kw, 450-rpm generator with belted exciter which went into operation late in 1956. An Elliott turbocharger may be seen above this generator. There's another one on the other end of the diesel. zs II. k) TOPPING TURBINE SERVES STEEL. MILL MODERNIZATION >6n. : The Elliott 10,000-k.w noncondensing turbine- generator unit illustrated here was recently put into operation by an eastern steel plant. The "topping" turbine-generator is part of a fuel and power modernization program. A pig-iron expan sion program had increased the supply of blast furnace gas. So a new boiler was installed to burn blast furnace gas and also to operate at higher steam pressures than the older boilers. The plant had been generating part of its total power requirements and with the increased load ulting from the pig-iron expansion program it would have been necessary to purchase twice as much power as was being generated. So the tur bine-generator was installed to operate with steam at 850 psig, 900 F, and exhausting at 200 psig to a steam system which supplies turbines driving blast furnace and coke oven compressors, boiler auxilia ries, etc. Electricity is generated at 13,800 volts, 60 cycles. Voltage regulation is Elliott design. The 510,000,000 modernization is calculated to produce annual savings of approximately 53,200, 000. The turbine-generator itself is figured to produce about 51,000,000 savings annually. wenpAX. sumwcr teas zz SERVES MISSILE EFFOl By JAMES A. SNYDER Mancgmr, Gor*rnmnf Projects Division, Air Productt, Inc. Time: Early 1955. Place: Washington, D.C. The Defense Department has met. Liqu oxygen--the mainstay oxidizer of the missile pr gram--is in short supply. Without it the missi program is greatly impaired. Military demanc encompass a substantial percentage of the tot national capacity. For each missile shot requires charge that is huge in terms of convention oxygen uses. Liquid oxygen--LOX--is needed quickly an in quantity. Defense Secretary Charles E. Wilson announci this decision: the Military must build its owi on-location supply. LOX for industry is not avai able in sufficient quantity, or in time. The Vai guard, the Redstone, the entire Air Force IRBfl and ICBM missile program needs liquid oxygens remote testing sites far from commercial source: Shortly thereafter Air Products, Incorporate* of Allentown, Pa., moved men and machines 300 miles. Then a remote area north of Los Angele hummed with activity. Soon, amid a cluster i buildings, came tall, rectangular "boxes" (insu lated housing for low-temperature equipment, als known as "cold boxes") . . . then piping ... an' machinery . . . like Elliott motors, reciprocatin: compressors, and Air Products low-temperator processing equipment. A later "box" was soon added. And a fiftl Elliott motor. One of the first of the Air Force' own liquid oxygen generating facilities was pov ready to go. Designed and constructed by Air Products^th' Santa Susana LOX station is now in operatjoi supplying vital LOX to the missile program Though Air Force owned, they are operatetfb; Air Products by request of the Military. ^ The installation of the Elliott motors was^ac complished by Air Products technicians, wU' Elliott installation service assistance. Since start- ` up. the five 4000-hp synchronous motors have 11 performed trouble-free, exceeding name-plate jpccilications. In each of these five low-temperature units a 'T compressor and expander are connected to an f Elliott MK)0-hp, 4000-volt, unity power factor syn- clironous motor. They're directly connected to the . jir compressor shafts, and power is returned to the i~ e,,gine crankshaft by the expanders. Switchgear on the original motors also came 1 fiom Elliott. This gear permits "`across-the-line" starting on full voltage. The compressors--reciprocating five-stagers that >- A Santa Susana liquid oxygen facility, nestled in tlie mountains e of Southern California. The "Cold Boxes", which contain the Air Products low-temperature plants, are seen between the two large Is structures. The smaller of the two buildings is a storage facility, il while the larger houses compressors, expanders, and motors. The a LOX is transp<*rted in trailers to a nearby missile testing site. <1 " Missile being readied for launching at night. LOX. being produced at a system of installations throughout the country, such as Santa Susana, is the main oxidizer in the missile program.  Cold boxes, with vcnetian-blindlike freon compressors in the fore ground. These "boxes" (insulated protection for processing equipment) house minus 300 F temperatures. Center--A liquid oxygen semi trailer, specially built to withstand temperatures of minus 300 F is loaded at Santa Susana for trans port to a nearby missile testing site. One of five Elliott 4000-bp, 277rpra synchronous motors at the Santa Susana liquid oxygen station. Motors are directly connected to Bve-stage compressors, and also to expanders. I build up 3000 psig pressure--are of the mull opposed cylinder variety and operate at a speed. 277 rpm. These pressures--204 times as severe i those we live under--coupled with cryogenic (e tremely low) temperatures of minus 300 F ar Air Products design and manufacturing skill pr duce the final liquid product. Southern California Edison installed a 15,00 kva substation on the site to deliver an average' 8,500,000-kwh per month at 4160 volts to dm the motors day and night. Power lines had to 1 strung over rugged terrain to reach the remo installation. And day and night, as the motors power tl compressors and expanders, these Air Produc plants are liquefying large, tonnage quantities oxygen and nitrogen in vital support of the I< and-IRBMs--intercontinental and intermedia range defenders of the free world. Electricity is tl only essential utility. This facility is an example of how a priva industry, such as Air Products, works in clo cooperation with the United States govemmer helping to establish a vital, dependable link in tl defense of freedom. It also means that the Allentown firm, reco nized by the Military and in industry as a lead in the blossoming field of Cryogenics, has chos< Elliott for dependable equipment to help naa) LOX the "mainstay oxidizer of the missile age POWEMFAX. l powercrax Tlie young couple were hard pressed for money ami the bride prepared hamburger in as many different ways as she knew how. On the 12th day she served still another version of chopped meat. As the husband surveyed it wearily he murmured: "How now. ground cow?" I'll give you a j>b. The (ir>i Ihiti>r J want you to do is sweep out Ibe store." I l*m :i college graduate.*' t j,,t)kay. I'll show you how.*' j>ln*'< like a washed-up pitcher--she's ftst her curves and can't gel a man out li ay mnn'. John Kraft of our composing puna lobter shift says they spent the week end rying otT his cousin. He was a vocalist tertaincr at the dog show, and his first lection was "Trips." At an agricultural college. a student having very low marks was voted "Most ikely to sack seed." An elderly retired couple fmm a remote mill town was visiting N. Y. for the first time. Tiie sights seemed to interest the old j- gentleman more than Ills wire, who finally of exclaimed. "John, the way you stare at IS 1 these city women is something scandalous. \ IhmIvM think youM never seen legs X- before." \d "Well." John mused, "that's what I was o- thinking mysi*lf." 0- AUnit all that man has learned in the of past 2~> y*fjirs. is ln>w to go faster. work ve less. s(N*nd more, and die quicker. be >te This old saying about making a silk purse out d` a sow's ear is a little out of dale. Now. the question is how a good looking gat ran gel a mink coal out of an oh I goat. Vvr cheeked the catalytic agent, determined the atotn flow rate and \ According la my calculation* ue\l e/*; better get the hell ant of here. H 99* . OWERFAX. SUMMER 1938 .Sul-h Hiking businessman was shown into office of prominent psychiatrist. "I've lost all desire to go on. doctor. Life has become too hectic, too conCased." "Y'es." said the doctor, ducking sympa thetically. "I understand. We ull have our problems. V-m'll need a year of treatments at 550 u week." There was a pause. "Well, that solves your problem. Doc. Now how about mine?" Married men can't understand why all bachelors aren't rich. At a Parent-Teacher Ass<x.'iutioii meet ing in a Mid-western town, they were dis cussing the poor quality of milk the children gol in schxd. "What this town needs," shouted one mother indignantly, "is clean, fresh, pas teurized milk--and we must take tlie hull by the horns and demand it." Many a joke sounds too good to lx* new. The train was behind time and the con ductor was in a surly iiummI. As he walked through one coach. a half dozen kids wen* running up arid down the aisle yelling while their mother calmly road a magazine. "Madam.'' he said coldly, "why didn't you leave half your children at home?" The woman looked up at the conductor and said, *'( did." It is hotter to give than to lend--and it rusts about the same. Jim: finfierl Burns wrote "To A Held Mouse." Jack: Did lie get an answer? Hard work Is an accumulation of easy things you didn't have time to do when yon should have. Two brothers in the retail coal business hud an intricate problem. Seems that one of them had taken an interest in the history and theory of ethics. "It's a line thing for you to study ethics," the first brother said, "but if I study ethics too. wImv's gonna weigh the oul?" The trouble with being punctual is that there's nobody there to appreciate it. He: "Darling, tell me those three little words that send me straight to heaven." She: "Go shoot yourself." A woman who makes u match for her daughter usually intends to act as referee. "You can't come in here and ask for a raise just like that." said the boss. "You must work yourself up." "But I did." replied the employe. "Look I'm trembling all over." Confidence, we read, is the feeling a man has before he knows better. \ Textin and a Kentuckian were arguing. "Why we've got enough gold in Ken tucky to build a gold fence six feel high around the whole State of Texas." "You just do that, son," replied the Texan, "and if we like it. . . we'll buy it." A fire in a backstage Indies' dressing room was put out in one hour and then it took live hours to put out the firemen. 1st Hen: "Have you been giving that rooster any special encouragement?" 2nd Hen: "Oh no--l just egg him on n little." ________ v Prosecuting Attorney: "You mean to say you had 16 beers and didn't move once from the table the night of the murder?" Grace: How's Abel Jones getting on with that schoolteacher he's calling on now? Hazel: Well, every time he goes U> see her she keeps him an hour longer for being naughty. _________ The minute men of today are those who can make it to the refrigerator and buck with a sandwich while the commercial is on. *. - STEAM AND GAS TURBINES 4 Turbine-Generator Units--Mechanical Drive Units--Power Recovery Turbines---HighSpeed Reduction Gears ELECTRICAL EQUIPMENT Motors (1 hp to largest)--induc tion. wound rotor, synchronous, d-c, brakemotors, gearniotors-- Generators (all types a-c and d-c)-- Motor-Generators--Synchronous Condensers--Slip Couplings HEAT TRANSFER APPARATUS Condensers and Ejectors--Deaerators and Deaerating Feedwater Heaters INDUSTRIAL PROCESS EQUIPMENT Centrifugol Compressors--Steam Jet Ejectors--Condensing Equipment--Power Recovery Gas Turbines CENTRIFUGAL COMPRESSORS AND EXPANDERS For industrial process applications (Electric motor, steam, or gus turbine driven) TURBOCHARGERS AND SCAVENGING COMPRESSORS FOR DIESEL ENGINES Turbochargers for Two-Stroke Cycle and Four-Stroke Cycle Engines-- Scavenging Compressors for TwoStroke Cycle Engines STRAINERS-FILTERS -/ '* Strainers (Twin, Single, Oil. Self-Cleaning)-- . Filters and Grease Extractors TUBE CLEANERS AND EXPANDERS For ull sizes of Tubes-- Tube Gages, Plugs, etc. " v-.- 'a * Hi * --; t* i COUPLINGS Resilient Flexible - f<Deecriptiee bulletins of any of these productm miU adty be enl upon request. DISTRICT OFFICES 4 Atlanta 5...................................3127 Maple Drive**! Boston 35.................................1330 Soldiers Field P Buffalo 2......................................... 807 Crosby Bufl Charlotte. N.C.................... 1707 Liberty Life Bufl Chicago 70.................................. 6100 N. Pulaski | Cincinnati 6................................ 2337 Victory Park Cleveland 11.......... 1319 National City Bank Bufl Dallas 6................................................. 5738 CentralExpress Denver 3.......................... 220--655 Broadway Buil Detroit 3..............................800 West Seven-Mile I Houston 3............................... 1209 Hutchins S Indianapolis 18..................... 3721 N. Keystone Av Kansas City 11............................. 514 West 75th S Los Angeles 15............................711 W. Olympic I Milwaukee 3........................................ 711 N. 4th S Minneapolis 23........................... 2101 Weal 78th S Newark (Bloomfield), NJ........ 100 Bloomfield Av New Orleans 13........................ 256 Lee Circle Bui New York 13......................................271 Church S Philadelphia2... .226 South Sixteenth Street Bui Pittsburgh 19............................................ 718 FrickBui Rockford, III................................ 401 West StateS San Francisco 1............... 2350 Equitable Life Bui St. Lou;s 3......................................... 1221 Locust S Seattle l................................................. 1101 VanceBoi Tampa 2, Fla.......................................308 Tampa 5 Tulsa 3......................................................222 MayoBui Washington 1, D.C.. . .Washington Gas Light Bu: SUBSIDIARY Elliott Turbine & Electric Company of Canada 1835 Yonge Street, Toronto 12,0> Western Sales Office........837 West Hasting! Vancouver, British CoU REPRESENTATIVES Birmingham, Alabama.. ... General Machinei 1600 Second Aven Portland 14, Oregon----- .... J. A. Tudor & A 1004 S. E. Belmont Seattle 1, Washington . . ___ J. A. Tudor & A 2605 Western A `Montreal 2. Que............... F. S. B. Heward & Co. 620 Cathcart Toronto 12, Ont............... F. S. B. Heward & Co * 1835 Yonge Havana, Cuba.......................... Companla Impor Skilton, S.A., P. 0. Bo Mexico, D.F............................. Tecnica y Equipo Monterrey 10. San Juan, Porto Rico........................................'I Warehouses Corp., P. O. Bo Santiago, Chile, S.A...................... Compania Mj ' Commercial Salt Hochschild, SA., Casiil Honolulu, T. H...Hawaiian Equipment Compan Manila, Philippines................Atkins, Kroll 40 121 Myere BuUding, 12th StreeL Pb* Also representatives in otherforeign eounlrie Approved teroice shops and distributors dnUficnUy throughout the United States. ` * ELLIOTT ` Hoodqvartors, /Turbins*, Hsot Troiwfor Equi JEANNETTE. PA- Mochanicaland< Turbochor^r*, Accaworto. Crockor-Whoalar Plant* vGsnorator*. COMPANY A DIVISION or CARR IKR CORPORATION RIDGWAY. PA. SPRINGFIELD. O. Motors, Generators A Dad Kldgway Plant' .Urf.W.._ii.5TjnuKh|jbC,,leCconeurp*.nnExop. ondmn. NEWARK. N. J. Hcto fw{ Tub. CUon.r^ '