Document ren2JnjLMDZOodvajG876brpG

Ln.omun 1C Recently installed cross-drum, water-walled boiler floats on line as original boi/ers are base loaded! \ , ,> , .\ \ r 'V STOKELY FOODS, INC. REDUCES COST OF STEAM 33 CENTS PER 1,000 LR After an extensive survey, instead of greatly increasing steam This boiler has a capacity of 50,000 capacity, this company added one new boiler and changed over to lb of steam per hr and is operated at 150 psi. saturated. The furnace volume alternating current to improve efficiency from 62 to 78.2%. Even is 2,050 cu ft, and a spreader stoker, with a grate area of 126 sq ft, is au higher efficiency is expected when the plant is 100% completed tomatically controlled. In addition an integral economizer, having a heating surface of 975 sq ft, maintains the v J. P. RUTLEDGE, Development Engineer feedwater at 212 F. Stokely Foods, Inc. Overfire air, drawn from the ash pit, is blown into the furnace at low pres sure, and smoke is held at the minimum. The two original boilers will operate AFTER an extensive survey of the Stokely Foods, Inc., plant in In at 4,160-v. "from the local utility and reconverting the entire plant to a-c op dianapolis, engineers found the over alleration. The latter system was deemed power plant efficiency was only 62%. more efficient. at base load, while the new boiler will float to effect a good steam balance. Coal Handling Analysis also indicated the boiler house Furthermore, cost of two additional Indiana coal is delivered by rail and was not the full cause of this low ef boilers, necessary coal and ash handling unloaded over a track hopper. Dumped ficiency. but that non-condensing tur equipment, and increased water treat coal is lilted by means of a bucket con bines driving d-c generators were very ment plant would have been prohib veyor to an overhead bunker, which has inefficient. A careful study of two pos itive. The new system is now in opera a capacity of 70 tons. Coal drops from sible solutions was made, namely; (l) tion and boiler house efficiency has in this bunker through a meter into in installing enough boiler capacity to take creased to ~8.2%. Cost of 1,000 lb of dividual spouts leading to boiler coal care ot all processing needs and in steam has been reduced 33 cents. hoppers. Each boiler has three separate stalling additional d-c generating equip One water-wall integral boiler, hav spouts leading to the stokers. Entire ment; and (2) installing one boiier to ing a total heating surface of 5,860 sq coal teeding system is controlled au take car-:- ot the increasing processing ft. was placed into operation alongside tomatically. This in itself has increased needs, rarchasir.c alternating current. the tv-o or dinal boilers earlv this vea:. oper.uinc efficiency considerably. RS-000169 72 1/17/03 INDUSTRY AND POWER August, 1950 NUECES August, 1950 Voi. 59. No. 2 '] RESEARCH MANUFACTURERS and industries have always sought to improve their products. 1. Research^hould be in a relatively autono mous position. It should exist and contribute They have always sought to develop new ones. in its ovjiYright; it ^hould be parallel and not Not too many years ago, the approach was en tirely empirical--all the emphasis was on "tryand-see" operations based on intuition and know-how. subservient to sales, production or engineering. 2. It must be conducted at a relatively con stant level, providing continuity of effort and reasonable security to the staff. No research Productivity of mere inventiveness, with em program will be successful if its budget follows phasis on mechanical ingenuity, began to .fade violent fluctuations of business cycles. at the beginning of this century. And asdt be gan to fade, organized science began to'become effective in promoting industrial prp^ress. To day, research is big business. Abqut one billion dollars is spent annually in industrial and gov ernment laboratories, by universities and by research foundations. 3. The research man must have freedom and opportunity for individual action. Research cannot be confined to a strait jacket of rigid regulation and rules or it becomes unproductive. Scientific knowledge on which industrial re search is based is so vast and its various cate gories so specialized that only the largest cor It is claimed in many quarters that a billion porations can hope to support modern research dollars a year for research is insufficient; that it should be about two billiqns if the optir organisations..--This indicates the need for 'greater support otNresearch foundations by welfare of our country is tobe maintained in small and medium-sized industries. They could, peace and war. This claim is based on fact: several industries have demonstrated that an and should, give mote support to fundamental research programs of colleges and universities. average expenditure of two per cent of their gross sales on research leads to the maximum in quality and quantity of goods produced, as well as maximum profit. Parallel expenditures by all industry would attain the two billion dollar figure. Too often.^hen small industries support re search foufidations and university research pro gram^ they expect immediate practical benefits on. particular projects. To say the least, that is shortsighted. C. C. Furnas, director of the Cornell Aero nautical Laboratory, has often emphasized the problems involved in industrial research. In cluded is the fact that many industries, par ticularly small and medium-sized ones, have no research in the modern sense of the word. Others have practically none. They are vulner able because they can't keep up with the pro cession. And where industrial research labora tories do exist, the following three important items for successful operation are often dis regarded. Research has become such a predominating factor in the American way of life that industry, both large and small, cannot afford not to give it maximum support. This is not to say that there would be any danger of the pool of knowl edge of scientific research and development dry ing up. The general social trend is such that if free enterprise doesn't support basic research, government will. In fact, this phase of social ization has probably advanced as far as is safe for our future sound economy. William J. Hargest, Editor INDUSTRY AND POWER * August, 1950 R8-000180 1/17/02 NUECES 54 in. L D. 48 in. tD Cinder return system Traveling grate spreader stoker 14-0'wide x tO'-O long Operating floor, Economixer aids boiler efficiency by maintaining boiler feedwater at 212F "^Induced and forced draft fans run ^Stitinuously because of the high re finance offered by the dust collectors, e&nomizer and stack. Flyash is trapped ife dust collectors and picked up and returned to the ash pit by means of a high pressure ejector system. Soot is | it...brown twice daily, and smoke is kept 3P,the minimum at all times. af-Steam is distributed to processing and rarbine operated equipment at 150 psi. These turbines are non-condensing and dfchaust at 2 psi back pressure. High ^fessure steam is reduced through a Pressure reduction station to 5 psi. which is necessary for food processing. Tflbe heating system, operated at 2 psi, t!P made up of non-condensed steam fFom the processing units and turbines. Make-up Water nfMake-up water for the plant is ex ceptionally high, in fact in the summer time 90% is required. This high 10 ,rr -- ZO'-W/q Fly ash trapped in dust collector is picked up by an ejector system and returned to the fire box. The ash drops into the ash pit and it is removed mechanically amount of make-up is caused by con tamination of steam as it comes in con tact with sealed cans in the cooking process. There is a certain amount of food spillage on the side of the cans when they are filled. This spillage is washed off in the submerged heaters, and therefore the hot water removed from the autoclave is wasted. In this heating process, hot steam is injected directly into the heater. In such a method, the steam not only acts as a heating agent but a mixing agent to maintain an even water temperature. ei ,1 PRINCIPAL EQUIPMENT IN STOKELY FOODS. INC. PLANT ffcfegrol economiier Spreader stoker Cool handling equipment domb uslion controls toiler leedpump Boiler feedpump turbine Boiler feedpump motor . Soot blowers Flow meters Overfire air ton ........................ Riley Stoker Corp. .......................... Riley Stoker Corp. .................................. Riley Stoker Corp. ..Fairfield Engineering Co., The ............................................ Hagan Corp. .............................. Dean Hill Pump Co. .......................... Dean Hill Pump Co. Crocker-Wheeler Electric Mfg. Co. Diamond Power Specialty Corp. ..Republic Flow Meters Co. ....................Clarage Fan Co Overfire air fan motor ... Induced draft fan .......... Induced draft fan motor Forced draft fan ............ Forced draft fan motor Switch gear ...................... Plug-in bus duct .............. Motor generator sets .. Air compressors Air compressor motor . .......... Crocker-Wheeler Electric Mfg. Co. ................................American Blower Corp. .......... Crocker-Wheeler Electric Mfg. Co. ................................. American Blower Corp. .......... Crocker-Wheeler Electric Mfg. Co. ..............................I-T-E Circuit Breaker Co. .................. BullDog Electric Products Co. . Westinghouse Electric Corp. General Electric Co. Worthington Pump and Machinery Corp. Reliance Electric and Engineering Co. INDUSTRY AND POWER * August, 1950 RS-000161 1/17/02 NUECES 73 I r*-- During the winter make-up runs be tween 30 and 40% because of the re turned condensate in the heating sys tem. Originally steam at 130 psi was delivered to two non-condensing tur bines, which drove a 500 and a 350- kw d-c generator. Current was de veloped at 280-v, and these units sup plied all the necessary power to drive the d-c electrical equipment through out the powerhouse and processing units located in the plant. , Steam Balance As these turbines were non-condens ing it was impossible to have a proper steam balance. In the new system dual operated processing and powerhouse equipment has been installed. This con sists of an electrical driven and turbine driven unit. To insure a good steam balance, the turbines are placed into operation whenever there is a surplus of steam. To start the changeover, two motorgenerator sets, 500 and 300-kw, were installed and connected to the pur chased power supplied. These d-c gen erators were connected to the old plant electrical distribution system, and d-c operated apparatus continued uninter rupted. However, a temporary 220-v a-c three-phase line was installed, and a-c equipment was tied in as the replace ments were made. The new electrical equipment will be 220/440, threephase, 60 cycle and all permanent bus duct equipment being installed will be 440-v. An analysis showed that it would TABLE 1--PREDICTED PERFORMANCE DATA 1 1. Steam output, pounds por hour 2. Furnace liberations, Btu por cu ft por hour 3. Enc.u air at bollar outt.l, % 4. Coal, pounds par hour 5. Air, pounds por hour 6. Air, cfm )S,000 9500 53 1,720 22,500 5,100 45,000 28,900 35 5,240 60,500 13,700 SdJ si u. 15,j 7. Stoam prossuro at bollor outlot, psi 6. Foodwator temperature, F Air tomporaturo, F 150 150 212 212 00 80 1 10. Exit gas tomporaturo. F 11. Draft lossos. In. of wator Furnaco draft Bollor draft 435 590 1 0.1 0.1 0.1 0.7 Dust collector (Bubar) Outlot dampor and flues Total draft 0X5 0.3 0.05 0.4 ox 1.5 12. Air resistance. Inches of wator Air duct Grate and fuel bod Total resistance 0.1 0.5 0.2 1.3 0.3 1.8 13. Heat balance, lossos % Dry gas Hydrogen and moisture In fuel Moisture in air Unbumed combustibles** Radiation Unaccounted for Total loss 14. Efficiency of dust collector, % 15. Efficiency of unit 10.17 5X3 J2S 1X0 2.35 1X0 21.5 W 78.5 12.90 5.64 .31 1.50 .95 1.50 22.8 85 77.2 13 1 16. Steam quality--Not more than '/i% moisture with boiler woter concentration lest than 3500 ppm. * Bated on reburning dust collector fly ash. be cheaper to run in the temporary 220 v line, as some equipment had been operated at this voltage. At the present time 440-v plug-in bus ducts are planned for each floor of the building, and all 220-v equipment will be eventually connected to this duct. As all electrical equipment pur chased to date is 220/400-v, it will Jjg a simple matter to change the 3 pha& motor wiring to accommodate this hig]^ er operating voltage when complete^ Purchased Power Purchased power is received at 4,1 *< One of two MG sets that supplies 280-v power for d-c operated equipment, After change over to a-c, only the elevators and cranes will utilize direct current v and stepped down in a transform^ bank to the necessary 440-v. At the present time with the temporary 22,<|U v bus duct, further stepping down power is necessary. This, of course, ^s, only a temporary measure and will eliminated when the system has beqn changed. Main service, as planned, wj$ be 2,000 amp throughout. The only maining units to operate on d-c will eg; the elevators and cranes. Lighting segift ice is supplied through individual trans formers located on each floor, and W will be stepped down to 110-v. When necessary, fractional hp motors will tied into this same 110-v circuit. (,;j Total demand of treated water, for processing and steam, is 1,200 gpm. Daily consumption, which includes processing, steam and cooling water, is 1,700,000 gal. Of this only the city water is treated as the hardness is on|j| 15 to 17 gr as calcium carbonate. TIki well water has an average hardness Of 32 gr as calcium carbonates, and in dition it contains considerable amount! of iron, which would not be desirably for food processing. Therefore, this water is used only for cooling purpostf; while the treated city water is used foi actual food processing. 74 RS-000162 INDUSTRY AND POWER * August 195C 1/17/02 Ml IFCES