Steam and hot water fitters' text book; prepared for the steam and hot water heating course at the New York trade school

Front matter

n r ^ DUfi^^ i ater itters' Text Book wmPM:

Steam and Hot Water Fitters^ Text Book

Prepared for the Steam and Hot Water Heating Course

Preface

Early in the summer of 1894 I was invited by the Advisory Committee of the New York Trade School in the Steam and Hot Water Fitting Department to deliver two lectures a week to the class, for twelve weeks of the course, and also to give such aid and advice as might assist in successfully inaugurating the work. Having decided to undertake the work, I discovered that no text book had ever been prepared, and that the course therefore would have to be created. It was with a view to meeting this deficiency that the lectures were prepared, which after delivery were published in The Metal Worker, and now appear herewith in book form. It is believed that these lectures will be particularly appreciated by those who wish to master the principles of steam and hot water heating. The definitions in the beginning deal with the appliances, and little by little the scholar is led on until at the close he is told how to figure surfaces and lay out plans and install heating apparatus, with all necessary piping. In a word, the whole subject of steam and hot water heating is covered in a simple way. and it is believed the lectures in the form of a text book will prove of value to all who wish to acquire information in this department. While primarily addressed to young students, the text book will be found of great advantage to those in other lines of trade who wish to take up steam and hot water heating.

Thomas E. McNeill.

New York, June 22, 1S96.

Chapter I. Tools, Fittings And Pipe

Question 1. What are the names and applications of the various hand tools used in steam and hot water heating work?

Answer. Tools.— The names of the tools used in steam and hot water fitting are : Rpe cutters (Fig. 1) for cutting

U zi

Fig, S.^Tap and Dies,

Fig, l.—Pipe Cutter,

Fig, 4. — Common Pipe Tongs,

Fig, 2. — Stock and Dies,

off pipe ; stocks and dies for threading pipes (Figs. 2 and 3), usually from % inch diameter up to 3 inches or more. The usual thread is standard right hand, but a left hand thread is often used. There are plain or standard tongs (Figs. 4 and 5), a different size being used for each size of pipe. All those of special make are adjustable (Fig. 7) for use with different sizes of pipe. Others for larger sizes of pipe are called chain tongs, or wrenches (Fig. 6). There are many kinds of tongs and wrenches manufactured.

Fig, 6. — Chain Tongs,

Fig, 5.^Coil Pipe Tongs,

Fig, 7, —Adjustable Pipe Tongs

Fig, S,^Adjustable Wrenches,

Monkey wrenches of various sizes, adjustable wrenches (Fig. 8), hammers, chisels, files, etc. ; pipe vises, swivel and angle pipe vises and hinged pipe vises for large sizes (Fig. 9) ; combination vises, pipe and bench, or machinist work, swivel vise and others, ratchet drill (Fig. 10), etc. (Fig. 11).

Q, 2. What are the names of the principal machine tools used in cutting and threading pipe, tapping holes, etc. ?

A, Machine Tools. — Pipe cutting and threading machines made by different manufacturers from J^ inch to 2 and up to 12 or 15 inches.

Q. 3. What are the names of the fittings in general use of all kinds?

Fig. ^.^ Large Pipe Vise.

A, Elbows —The principal fittings are elbows of all sizes (Fig. 14) and reducing elbows (Fig. 15). These are used to change the direction of main pipe or branches, with an easy turn ; 45-degree elbows (Fig. 16) of all sizes are used to change direction to angle of 45 degrees, and in combination with other fittings to make easy turns in any direction. There are elbows with a side outlet.

Tees.— Tees (Fig. 17) of all sizes, also reducing tees (Fig. 18), with outlets both on the run (Fig. 19) and the side (Fig. 20) ; these are used to take out a branch supply and at the same time to continue the direction of main either of the same size or less.

CROSSES.—Crosses (Fig. 21) of various sizes of outlets, also reducing crosses, are sometimes used for continuing the

Fig. 11,^ Center Bit

Fig, 12,— 'Return Bend Wrenches,

run of main in the same direction and taking out two supply outlets at the same time.

Return Bends.— Return bends are used of all sizes from % inch up to 4 inches ; they are made close (Fig. 22) and open (Fig. 23), the first with web between, the latter without.

Flange Unions.— Flange unions (Fig. 24) are made of all sizes from % i^ch up to 12 inches and are used chiefly fitters' text book.

Fig. 13— Pipe Pliers.

Fig. 15,^ Reducing Elbows.

Fig. 11.— Tee. Fig. 1'^.— Reducing Tees,

Fig. 19.- Reducing Tees on Run.

Fig. 20. '^Reducing

Tee on Outlet.

to connect up large pipes or where the pipes to be connected cannot be sprung.

Bushings. — Bushings (Figs. 25 and 26) are made of all sizes from % inch to 12 inches, and are used for reducing the sizes of pipes where fittings for the purpose cannot be obtained, thus making two joints instead of one, as with reducing fittings.

Reducing Coupling.— Reducing couplings (Fig. 27), from 3^ inch to 12 inches, are used for the same general purpose.

Fig. 22.— Close Beturn Bend

Fig. 21.— Cross.

Fig. 2i, — Flange Union,

Fig. 23. ~ Open Beturn Bend.

Y-Branches. — r's (Fig. 28) are made of all sizes from 3^ inch to 6 inches, and are usefully and advantageously employed, particularly in hot water or steam work, giving an easy change of direction of pipe.

Offsets. — Offsets are made of sizes from % inch to 6 inches, with offsets 4 inch, 6 inch and 8 inch.

Caps and Plugs.— -Caps and plugs (Fig. 29) are made of all sizes from J^ inch to 12 inches, and are used for closing the ends of pipes and outlets of fittings.

Lock Nuts. — Lock nuts are of all sizes and are generally used for making joints on long threads with some form of packing.

fitters' text book.

Fig. 25,— Bushings,

Fig. 26.— Reducing Tee with.

Bushing.

Fig,2'6.— Y 'Fitting or Y-Tee. Fig. 27, -^Reducing Couplings,

Tapped Plug. Cap. Plug.

Fig, 29, — Cap and Plugs,

Fig. 30. — Union.

Fig. Si. —Plain Fig, S2,— Eight Fig. 33.— Shoulder Fig, 34. Coupling, and Left Nipple, Close

Coupling, Nipple,

Unions.— Unions (Fig. 30) are made of sizes from J^ inch to 4 inches, and are used to connect up pipes without spring, and can be easily taken down again.

Couplings. — Couplings are of three kinds, plain (Fig. 31), tapped right hand ; ribbed on outside, usually tapped right and left (Fig. 32), and reducing couplings (Fig. 27), mentioned before. The plain are generally used and come on the ends of pipes. Right and left are used to make up joints where ample spring can be obtained.

Flanges. — Cast iron single flanges are generally used for rests or supports.

Nipples. — Nipples are of two kinds, called shoulder (Fig. 33) and close (Fig. 34) nipples, and are threaded right, or right and left hand. The shoulder nipples usually range from 2 inches to 63^ inches long, depending on size. The close from 3^ inch to 4 inches diameter, and from IJ^ inches to 5 inches in length.

Ceiling and Floor Plates.— Ceiling plates are made from J^ inch to 4 inches. Floor plates from 3^ inch to 4 inches. The first are used around pipes passing up through ceilings to close and protect the opening around pipes. The last are placed around the pipes where passing through floors, etc., as a finish and protection.

Branch Tees. — Branch tees (Fig. 35) are cast iron pipes with tapped outlets on one side, varying in number, sizes and distance apart, with outlets of different sizes on ends, and sometimes outlets on the back or side for special purposes. They are used for making wall circulation coils, with spring pieces of pipe to take up the expansion, and are called, according to arrangement, miter or corner coils.

Hook Plates.— Hook plates (Fig. 36), ring plates and expansion plates are all used for supporting the pipes of wall coils, and are usually fastened to wooden strips made fast to the wall.

Q. 4. Are there many special fittings made? If so, what are their names and for what purposes used ?

A, Eccentric Fittings — Eccentric fittings are not com-

FITTERS' TEXT BOOK.

Fig. S5.— Man'

ifold or Branch Tee,

Expansion Single Cast Iron Plate. Hook Strap.

Plate.

Fig. S6,—ffook Plates for Coils.

Fig, S7. ^Eccentric Brass Globe Yalve Iron Body Globe Stop Coupling, Cut Open. Valve with Yoke.

Fig, SS.— Globe Valve.

inonly used, but are of special value. Ecceniric Lees and couplings (Fig. 37) may be used in the steam supply mains and other pipes, as they permit of a level bottom in the main pipe and a clear and prompt relief of the water of condensation. Division tees also permit a direct connection of two return water pipes in one line. Double branch elbows are also of use.

§.5. Of what material is the pipe generally used in a heating apparatus made ? How is it made ? Is cast iron pipe ever used for mains or circulations ?

A, Pipe. — The pipe formerly used in some classes of hot water heating, and some even now, was made of cast iron ; but it was heavy and slow in transmitting the heat, but now in nearly all house work wrought iron pipe is used. Occasionally in factories cast iron pipe is now used for radiating the heat from steam, but the supply mains are usually of wrought iron. In almost all other cases wrought iron pipe is used for mains, risers, returns, etc., but cast iron is largely used for radiators.

Q. 6. What sizes are usually made or kept in stock? What are the various thicknesses ?

A, Sizes of Pipe. — The sizes of wrought iron pipe kept on hand vary from ^ inch to 12 inches or even 15 inches, and vary in thickness from 0.068 inch up to 0.366 inch — 1-inch being 0.134, 2-inch, 0.154, 3-inch, 0.217, 4-inch, 0.237, 5-inch, 0.259, 6-inch, 0.280, 8-inch, 0.322.

Q. 7. Is there any pipe made of extra thickness, and for what purpose used ?

A, Extra Strong Pipe. — Extra strong pipe is made of regular sizes from % inch to 4 inches diameter. It is used for extra heavy pressures, or where liable to rapid deterioration, as connections around boilers for water supply and blow off.

Q. 8. What is the mode of measuring or designating the various sizes of steam pipes ? Also of boiler tubes ?

fitters' text book.

A, Pipes and Tube Measure. — The mode of measure ing steam and water pipe is by its interior diameter. Boiler tubes are by the outside diameter.

Q, 9. What are the names of the different styles of valves used, and how best utilized ? Also of check valves, and how used? Safety and other valves ?

A. Valves. — The valves most used on all main steam pipes and around the boiler are either globe (Fig. 38) or angle (Fig. 39) valves ; sometimes gate valves (Fig. 40), which

Brass Ang-le Valve Cut Open.

Brass Opposite Angle Valve.

Angle Radiator Yalve with Union Outlet.

Fig, S9,— Angle Valves.

are slowly gaining favor ; on the bottom of risers, globfi valves ; around the radiators, chiefly globe and angle or ** opposite angle " valves, a special make ; gate valves on all hot or cold water pipes.

Check Valves.— Swing check valves (Figs. 41 and 42) are deemed best on the returns to the boiler, pumps, and all pipes conveying water ; for all ordinary purposes the common globe checks (Figs. 43 and 44) answer very well. '

Q» 10. What are the names of the devices used for hanging or supporting pipes in position, allowing for expansion and con'-^'action ?

A. Hangers. — Pipes are supported by hangers oi various special designs, for ease of adjustment and connection, with freedom of motion for the expansion and contraction of the pipes they support. Various means in the past have been used, such as straps, chain, etc.

Q. 11. What are the different modes used in making up joints when connecting the ends of two or more pipes? What materials are used for special joints?

Fig, 41. — Iron Body Swing Check Valve,

Fig, 43. — Common Brass Check Valve,

Fig. 40 —Brass Gate Valve,

Fig. 42.— Brass

Swing Check Valve

Cut Open,

Fig. 44. — Brass Vertical Check Valve.

A, Joints. — Different means have oeen used in making up joints. When the threads are good, a little linseed oil may be enough, or plumbago and oil, or red lead and oiL In making up flange unions the joints are made up sometimes with rubber ; again with asbestos paper, usudurian, copper, or canvas, oil and red lead. The gaskets are of endless variety.

[Fig. 45 is a shop interior showing fitters' benches made from pipe with pipe vises.]

fitters' text book.

16 stea:.i axd hot water

CHAPTER 11.

GENERAL QUESTIONS ON HEATING.

Question 1. What means and devices are generally used for heating dwellings, stores and large buildings of all kinds at the present time ?

Answer, Open fires, stoves, hot air furnaces, low pressure and high pressure steam and hot water.

Q 2. Which are considered best, all things duly considered ?

A. Low pressure steam or hot water.

Q. 3. How do these compare in first cost ana ease of management ?

A. The first cost of the hot water apparatus is generally higher ; there is little if any difference in the management, as they are both intended to be nearly automatic ; both require care and attention in firing.

Q, 4. To what special cases are such best adapted ?

A, In variable or moderate climates steam seems best adapted as its circulation and supply can be increased or diminished in less time, and it is more promptly responsive to any sudden requirements. In steadily cold or uniform climates hot water answers all purposes, for, while it needs more time to circulate and thus increase the radiating power, it is more even and maintains an uniform temperature longer.

Q. 5. How are these two systems best applied to their varied uses?

A. (1 . ) By means of radiators placed in the rooms to be heated ; this is called direct radiation, (2.) By a combiaation called direct-indirect, where the radiators are placed in the rooms and a fresh supply is brought in from the outer air by means of ducts near to and connected with the base of the radiators. The air is there warmed and rising up passes around the radiator pipes, then enters the room. Also by direct heat from the radiators. (3.) By indirect radiation, where the radiators are placed usually in the basement of the house and inclosed in boxes or chambers ; air from without is allowed to flow through the heated radiators, then through the ducts, made of tin or galvanized iron, to the various rooms requiring heat, the inflow into the room being regulated by registers and at its entrance into the cold air ducts by dampers. The circulation of the air is caused by its being expanded or rarefied by the heat, and thus made lighter ; it then rises up through the flues. This flow is often quickened by positive or mechanical means, such as fans, etc.

Q. 6. How are these radiators supplied with steam or hot water ?

A, By means of a boiler or generator placed, usually, in the cellar, and connected with the radiators by steam supply and water return pipes for the steam apparatus and water circulating main pipes and returns for the water apparatus. In both cases these are connected by branch pil)es to each radiator or coil.

Q. 7. What is steam, and how produced for use in steam heating ?

A, Steam is the vapor of water, generated in a closed vessel or boiler, and supplied, at any pressure desired, to radiators in the manner previously described.

Q. 8. What is hot water, and how produced for use in hot water heating ?

A. Hot water is water charged with heat to or near the boiling point in a closed vessel or boiler, and supplied through circulating pipes to the radiators and coils in the manner previously described.

Q, 9. What are the three terms used in aescribing the different modes of transmitting heat from one body to the other?

A. Radiation, conduction, convection.

Q. 10. How are these modes utilized in steam and hot water heating ?

A. Radiation, as the term is used in heating, is when the heat is transmitted directly to the object having a lower temperature than the source from whence the heat — in this case the radiator — comes and passes through the atmosphere to all objects surrounding it.

Conduction is where the heat passes from one object to another when in actual contact, as from steam to steam pipes, and so on.

Convection is where the heat is conveyed by some medium like air, etc., from one object to another, as in the indirect system of heating.

Q, 11. What is gravity?

A. Gravity is the tendency of all matter to approach the earth, it being the greater mass, as '' every particle of matter attracts every other particle in the direct ratio of its mass."

Q, 12. What produces the circulation of steam through the supply pipes and radiators of a steam heating apparatus ?

A, Steam being vapor of water, or water expanded by heat, is lighter, therefore moves in all directions and fills all space accessible to it ; as the heat it contains passes off, or is conducted off, its volume is reduced and the steam becomes water again, and it being then heavier flows to the lowest point provided for it. In the form of steam it is simply the conveyor of heat by circulation.

Q. 13. What induces the circulation of water in the flow pipes and radiators of a hot water apparatus ?

A, As water is heated it expands and, becoming lighter, rises to the highest point and gives up its heat ; the less expanded or colder descends, becomes heated and again rises, and so on. As the heat passes out from the water by conduction through the iron of the radiator into the atmosphere or objects in a room, the water becomes Leavier and descends to the lowest point provided for it. The water simply conveys the heat to the proper point, delivers it and returns for more.

Q. 14. What causes ^.xe return of tne water oack to the lowest point — generally the boiler — in either case ?

A. Its greater density, or weight, and the force of gravity in all such systems.

Q. 15. In what direction then snould the main supply pipes of a steam heating apparatus incline ? Also the return or water pipes ?

A. The main supply pipes of a steam heating apparatus should incline downward, from the boiler to the furthest point, or in the direction of the flow of the steam. In the case of branches or side supply pipes, however, this is modified, and they are usually inclined up to the point of delivery. The inclination of the return or water mains is the reverse of the steam, and is downward from the furthest point ta the boiler, in the direction of the flow of water,

Q, 16. In what direction should the main supply or flow pipes of a hot water apparatus incline? Also the main return pipes ?

A. The main supply or flow pipes of a hot water apparatus should incline upward from the boiler to the point of distribution, and in the same direction for the return pipes.

Q, 17. How should the main supply and return pipes of either system be run as regards their lateral direction ?

A, As directly as possible, with due regard to the construction of the building and the appearance of pipes in it, also the location of risers and radiators, avoiding all short turns where i)Ossible.

Q. 18. What is expansion? What causes it? How is it provided for in the erection of a heating apparatus ?

A. Expansion is the increased separation of the particles of matter, of all kinds, by the action of heat. The reverse, or cold, is the reduction of heat, which is followed by contraction. All materials are subject to like laws in expanding and contracting.

In running pipes containing steam or hot water, due provision is made to meet this in the arrangement of the pipes, by what are called breaks, expansion joints, swinging joints and radial arms.

Q. 19. In designing a heating apparatus for any purpose, what are the principal points to be first obtained, so as to provide for all contingencies and supply the amount of heat required, etc. ?

A. About the first information to be obtained is the geographical location of building, of what material constructed, how arranged, what it is to be used for, the points of the compass, the lowest outdoor temperature during winter, the temperature required in the rooms. Where the water supply is to be obtained, if constant and ample. Simplicity in construction, ample proportions of parts for all purposes, without excess, ease of erection, facility for repairs and convenience in management must always be provided for.

Chapter III. Low Pressure Steam

Question 1. In planning and proportioning self regulating low pressure steam heating apparatus for dwellings and buildings of moderate size, what parts and appliances are necessary and what are generally used ?

Ansiver, A boiler, either of the horizontal tubular, vertical tubular, sectional, made of wrought iron pipe, sectional of cast iron, or a combination of cast and wrought iron, with all self regulating attachments for controlling air draft, water supply, steam pressure and main controlling valves, etc.

Next, a complete system of main steam supply pipes and branches and return water mains, with all controlling valves necessary.

Next, a set of steam risers and water return pipes, with a valve in each lower branch pipe, except in small houses or when the one-pipe system is used, then one rising pipe answers for both purposes, one valve on the radiator and on each branch pipe below.

Next, where direct or direct-indirect radiation is used, one or more radiators in each room to be heated, with controlling valves, air valves, and pipe connections.

Next, if the indirect is used the radiators are placed in boxes or chambers in the cellar ; cold air ducts with dampers and regulators, metal hot air tubes running up to registers in rooms above, must be provided for.

Q. 2. How are the horizontal tubular boilers made, what castings are required ?

A. Horizontal tubular boilers are made of rolled plates of steel or iron, built up in section rings and held together by rivets in seams both horizontal and circular; the heads or ends are of flanged steel or iron plates riveted to the shell ; in these heads are the holes for the boiler tubes which pass from head to head and are expanded into the head plates by an expanding roller tool ; then there is a dome on the top of the shell of like material and make, and all of these heads are thoroughly braced to the sheets. In the dome head, en the shell, or in either boiler head is placed a man hole, and in the lower part of the boiler heads are hand holes, all fitted with covers and fastenings ; these are for cleaning out and repairing the boiler. In the upper part of the dome, and on the bottom of back sheet of boiler, are tapped flanges as outlets for steam outflow and return water inlet pipes. On each side of the boiler shell are riveted cast iron lugs for supporting the boiler on brick work. A part of the space above the tubes is for steam.

The castings required for horizontal tubular boilers are sectional cast iron fronts, including smoke box doors, fire and ash pit doors, cleaning out back flue doors, top amd bottom, grate bars, bar bearers, arch plate, and flame plate, buck stays, a channel beam for the back arch, and tie rods and anchor bolts, the last three to be of wrought iron.

Q, 3. How are they set, what materials are used, and how laid?

A, Horizontal tubular boilers are set in brick work (Fig. 46). The outer and end walls are made of best hard burned red brick, as a general thing, laid in cement and lime mortar. These walls are carried up above the boiler top, and capped with blue-stone coping. The lining of the furnaces, or fire pots, are of the best fire brick laid on flat in thin fire clay mortar with close joints, and occasionally header courses. The ash pits and a space in front of the boiler are paved with common brick on edge and grouted in with sand and mortar.

There is always one, and sometimes two bridge walls, beneath the boiler ; the front one is partly faced with fire brick, and often the space between the two is filled in and paved.

Q, 4. How are the vertical boilers made, what castings are required ?

FITTERS' TEXT BOOK.

A. The vertical boilers are made of sheets of steel or ii'on as the others ; some are plain cylinders without domes or lugs, set up on end on brick work and above the furnace, others have an annular construction on one end called the fire box formed by an inner sheet riveted to the lower head and the extension of the outer sheet of boiler ; the space between these sheets being filled with water.

The castings required for vertical tubular boilers are

Fig, 46.— £ricfc Set Horizontal Boiler,

(with or without a fire box) a cast iron bottom and top plate, the latter with a hole in it the diameter of the boiler, fitted with a cover in two parts, a cast iron ring for the grate to rest on, a grate, either dumping or fixed, a fire door and a swinging ash pit door set in frames, sometimes a cast iron base plate for bottom of ash pit and flue cleaning doors at the bottom of the down draft flue.

How are they set, what materials used, and how

A, They are set with the same materials as the horizontal tubular boilers. The simpler class have outer walls ot hard brick, and a furnace lined with fire brick, with a space for down draught around the outer shell.

The fire box vertical boilers are set in a similar manner; the outer walls are run up above the top of the boiler, and are capped by a casting, thus forming the smoke box ; with this the outer annular flue around the shell of the boiler is connected, the lower end being connected with the smoke flue, thus forming the down draught flue outlet.

Q. 6. How are sectional boilers made, and what castings are required ?

A. Sectional boilers are made of almost every posible shape and material, chiefly of a combination of case parts and headers with wrought iron pipe. One of the earliest styles was in the form of a box coil, so-called ; it had cast iron headers with wrought iron coil, made up with cast iron return bends. Others are made of inclined or bent boiler flues expanded into cast iron or steel headers, or wrought iron drums. Others are entirely of cast iron held together by wrought iron bolts, and are of many forms, the object being the same, but the results varied.

The castings required for setting sectional boilers are generally (depending upon their construction) cast iron frames and fronts, smoke, fire and ash pit doors, clearingout or dust doors for various parts of boilers, arch and flame plates, grate bars and bar bearers, buck stays with tie rods, and sometimes cast or wrought iron beams for carrying the fire bricks covering the top, or cover of fire chamber.

Q. 7. How are they set, what materials are used, and how laid?

A. The settings, in most cases, are only an inclosure of the various parts by outer walls of hard c ^mmon brick, and furnace and side lining of fire brick, covered on top by fire brick, supported by iron beams.

Others of these boilers are what are called portables — that is, without setting and easily moved.

Q. 8. What are the parts of the self regulating feed apparatus, how made ; how connected up with boiler and water supply ?

A, The parts of a self acting feed water apparatus (Fig. 47) are an oblong cast iron receptacle or skiell, sometimes round, or flattened on the sides and irregular in shape. A lever of brass with an air tight hollow copper sphere is fastened on one end, and two pivoting pieces at the other end ; beyond these is a projection with a recess to hold a rubber disk, or valve ; on the outer side of this cast iron shell is sometimes attached a glass water gauge ; on the top is a hole tapped for the steam connection ; on the bottom is another tapped for the feed to the boiler ; at the other end, below, is another tapped hole for tne cold water supply pipe.