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THESIS

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DESIGN AND CONSTRUCTION
OF POWER PLANT
MARQUETTE CEMENT MFG. CO.

Pu one tae

GEO. W. WILLIAMS
1909

 
THESIS

~- a
 

a -

1
A,
THE DESIGN AND CONSTRUCTION OF A POYER PLANT
for the

MARQUETTE CEMENT MANUFACTURING COMPANY,
La Salle, Illinois.

A

THESIS

presented to

The Faculty of the Michigan Agricultural Collese.

by.
~ we
George W! williams

For the Degree of

Mechanical Engineevry.

June 1909.
THESIS
STIAWEYE COO OOOTE L141 10 Te ONNY
SMUOM LNAW AO ANVILUYUOd ALLA IDM VIN

  
 
In choosing this subject for a thesis, it
is not with the idea of being able to present anything new
or of great magnitude, but rather to bring out the numer-
ous problems involved in the design and construction of a
modern power olant as encountered in actual practice. In
this particular case, however, there were features involved
in the location and arrangement seldom encountered in the
average plant and it was these that made it seen of suf-
ficient interest to warrant its description.

As industries are constantly being develop-
ed, the requirements for motive power are being increased
and to economically keep pace with these conditions, the
matter of careful engineering becomes of more and more in-
portance.

In the summer of 1905, the business of the
Marquette Cement Mf'g. Company had reached such proportions
that radical alterations in and extension to their plant
became necessary and to meet the constantly increasing de-
mand for cement coupled with the keen competition bstween
Manufacturers, the matter was one calling for thorough con-
sideration and planning.

The Company's plant is located near La Salle,
Illinois, in the valley of the Vermillion river, on a nar-
row strip of land between it and a range of rock bluffs
paralleling its course. The average elevation of the strip
is about thirty feet above the river at this point, while

~]—
the bluffs are forty feet higher at their edge, rising to.
a height of one hundred and fifty feet above the river some
four hundred feet farther back. A line of the Chicago,
Burlington and Quincy Railroad follows along the river on
the lower level, while a branch of the Illinois Central
runs along the top of the bluff.

The product of this Company is made from a
natural cement rock quarried from a mine in the bluff adja-
cent to the mill. From the mine the rock is hauled in
dump cars by an electric locomotive to the crushers where
it is broken into small pieces, then conveyed by means of a
belt to storage bins over the grinders. The grinders, or
ball mills as they are called, reduce the rock to a powder
which is fed into the rotary Kilns, where it is burned with
pulverized coal blown into the Kilns by specially designed
fans. This burning produces what is Known as a cement
clinker which, after cooling, is crushed and reground to an
impalpable powder and passed on to the storage bins where
it is allowed to age or season before packing.

The process is a continuous one and the plant
is in operation twenty-four hours a day during the whole
year with the exception of about ten days when it is shut
down for general repairs.

At the time mentioned the mill was grinding
about one thousand barrels of cement per day and the exist-

ing market conditions and outlook for the future were such

—~2-
‘

that it seemed advisable to double its capacity and, at the
same time, provide for future growth. Such an increase in
capacity would necessitate a complete overhauling of the
plant and its operation from the mining of the raw material
to the storing and shipping of the finished product.

Up to the time of remodeling, the plant had
been served by only one of the railroads, namely, the
Chicago, Burlington and Quincy, although the branch of the
Tllinois Central ran close by. To get the latter to run
a spur onto the property would open a way to other sources
of fuel supply and points of disposal for the finished pro-
duct and would materially affect the cost of plant operation
as will be later explained. To bring this about required
the purchase of additional property and the usual amount of
time consumed by railroad companies in such cases, but both
of these matters were, in due time, satisfactorily settled
and the attention of the Company was turned to the main
problem, that of remodeling the plant.

The general requirements and plans for the
changes in the mill proper were taken in hand by the Com-
pany themselves, who were guided by the experience gained
in the operation of the old one, and assisted in the engi-
neering features by the builders of the apparatus entering
into its make-up.

While the process itself is a simple one and
standard apparatus had been developed to carry it out, a

-3-
large amount of power is constantly required for each of
the various steps and upon the reliability of its source |
depends, in a large measure, the successful operation of
the whole plant.

When the matter of providing for the power
was reached, it became necessary to call in outside engi-
neering assistance and Mr. George M. Brill was selected to
carry on that feature of the undertaking. The conditions
then existing together with the general requirements for
the new plant were made a subject for an investigation which
resulted in a report setting forth the recommendations cover-
ing a new power installation.

The old plant was being operated both elec-
trically and mechanically, but experience and common prac-
tice indicated the advisability of complete electrification
in the new one. This is more easily understood when it is
considered that the process is carried on by units of mills,
grinders, rotary Kilns, etcetera, each requiring a large
amount of power and so arranged that to drive them by mechan-
ical transmission would necessitate the use of long lines of
heavy shafting, gears, chains and belts, which, in such a
gritty atmosphere, would consume a large amount of power and
entail considerable expense for maintenance and loss due to
break-downs.

The old power plant was located in one end
of the mill proper and as the latter was hemmed in by the

—4—
railroad and bluff on its sides and the entrance to the

mine and the storage bins on its ends, this space was not
only valuable for other purposes, but actually required to
carry out the plans for the new arrangement. There was,
however, sufficient space available at one end of the pro-
perty for the erection of a new power plant, and as the power
was to be electrical, the small extra distance to the center
of distribution was immaterial.

In the majority of power plants using coal
as a fuel, hand labor or special apparatus are required for
unloading and storing the coal and disposing of the ashes,
these conditions being looked upon as fixed and the neces-
sary charges or costs resulting therefrom borne and con-
sidered as a matter of course.

The natural conditions which existed at this
particular site, meke it possible and practical, without un-
due expense, to so locate, design and equip a boiler plant
that the common source of annoyance and expense in handling
the coal and ashes could be almost eliminated and gravity
employed to deliver coal to the boilers and remove the ashes
from them. With the Illinois Central spur extended onto
the property to a point above the proposed power plant, coal
could be delivered in drop—bottom cars to a storage bin
above the boilers, from which it could be drawn through
chutes to the grates which in turn would discharge the ashes
into suitable hoppers underneath. These hoppers could be

—5—
Placed at a height that would permit of cars on the
Burlington track being placed under them for the purpose
of conveying the ashes away from the plant. By the use of
properly constructed chutes and ash hoppers, regulated and
operated by the boiler room attendants, the coal could be
passed from the cars to the grates and the ashes removed
with practically no hand labor or power operated apparatus.
The difference in the cost of operating such a boiler plant
and one built along the lines of the old one, where hand
labor was emoloyed, is shown by the following calculations.
Assuming that 2000 boiler horse power would

be the average capacity in use and burning coal at the rate
of 4.5 pounds per boiler horse power per hour, 9000 pounds
of coal per hour or 108 tons per day of twenty-four hours
would be required and if the ashes amounted to 15%, there
would be 16.2 tons of them per day.
HAND METHOD.

Unloading 108 Tons of Coal at 744 =$8.10

Firing 108 Tons of Coal at 156 =16.20

Removing 16.2 Tons of Ashes at 12¢ = 1.94

 

Total : $26.24
GRAVITY METHOD.
Unloading Coal and Dumping Ashes $1.75
Firing Boilers, two shifts at $3.00 = 6.00
Total $7.75
  

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SECTION THRU

POWER PLANT

OF THE
MARQUETTE CEMENT MFG CO

 

 

 
With a gravity system and automatic stokers,
the coal could be delivered to the plant in drop—hottom cars
which would make it possible for one man or his equivalent
to unload the coal and dispose of the ashes, and one man in
eacn shift could care for the firing of the boilers. TO
realize this it might require an extra expenditure of
$10,000, but even so, the saving affected would in a few
years pay off the extra first cost.

With the river close by, a sufficient quanti-
ty of water for the operation of the plant could be obtained
with but a small expsnse for pumping.

The location relative to the mill, the loca-
tion of railroads, the elevations and the nature of the soil
all contributed to conditions practically ideal for the pur-
pose of a power plant and with proper design of the build-
ing or buildings and the selection of equipment, properly. in-
stalled, there should result a plant of exceptional economy
in operation and maintenance.

Without going into the detailed requirements
for increased power at that time, we were given to understand
that an installation of 2400 horse power of water tube boil-
ers, equipped with automatic stokers, and the same horse
power of cross-compound condensing engines direct connected
to gonerators of suitable capacity would satisfactorily meet
the requirements. Two ways of providing for this capacity

were open for consideration, One was to purchase new boilers,

_7—
engines anc generators of the type mentioned for the whole
equipment; the other was to use the old horizontal tubular
boilers and the belted engine-generator units then in ser-
vice as far as they would go and supplement them with new
apparatus.

The water tube type of boiler would be in
larger units than the tubulars, somewhat more economical
in the production of steam, more easily and therefore
cheaply operated and less expensive to maintain. More
important, however, was the fact that the old boilers were
built to carry pressures not to exceed 110 pounds, while
the water tube type could carry 150 pounds or more with a
consequent material improvement in the engine economy.

While the old engines might have been con-
tinued in service in the new plant, they were in units of
400 horse power, rather small for use in a new plant of the
proposed size. Aside from this and the low pressure for
which they were designed, they were far less economical
than first class cross-—compound units.

If the old apparatus were used, the building
would have to be considerably larger to house it on account
of the greater space required by the low pressure tubular
boilers and the belted engine-generator units. There
would be the expense of moving it, somes repairs would doubt-
less be necessary and sooner or later it would have to give

way to apparatus of the more modern type considered for

~8-
the balance of the equipment...

Continuous operation during the period of
changing over was also an important factor, as each day's
shut-down involved a loss of profits amounting to approxi-
mately one thousand dollars, and by leaving the old equip-
ment intact until the new plant could be started, this loss
could be avoided. Considered from every standpoint, if
the new plant was to be made strictly first class, it would
be better to install such new apparatus throughout as might
be necessary to properly meet ths requirements and thereby
gain the extra efficiency from the start.

The first plan considered was to erect two
separate buildings to house the boilers and engines, locating
them at different elevations. The boiler house would be
Placed on the top of the bluff, which would bring it at
such a height that a larver hopper holding a car or more of
ashes could be cut in the rock under the boilers and the
cars run under it through a tunnel cut in from the side
of the bluff. Practically all of the oxcavated material
could be used in the manufacture of cement so that the ex-
pense of excavation chargeable to the power plant would be
small. The engine room would be located at a lower level
and nearer the plant.

Upon further consideration this plan was
abandoned and it was decided to place all of the apparatus
in one building with the boilers and enginos’ on the same

~9-
level. The floor would be at such a height that cars could
be switched into the boiler room basement and clear the ash
hopvers, one of which would be provided for each boiler.
This latter plan was by far the better one as the first

cost and operating expense would be much less than would

be the case were separate buildings provided and the appara-
tus spread out over a larger area.

When the general location of the power house
had been fixed, a survey was made and levels taken covering
the area under condideration from the river to the top of
the bluff including the floor line of the old mill and the
Burlington and Illinois Céntral roads where they passed the
plant. From these levels a profile was prepared to serve
in determining the exact location and elevation of the new
power plant and its apparatus.

As a large quantity of water would be re-
quired for the plant, the means of economically supplying
it from the river was an important consideration. Two
methods of dcing this presented themselves, one being that
of locating the pumping apparatus at the river,which was
about 150 feet away. The other was to place the apparatus
in the power house and bring water to it by means of an in-
take. As the river during high periods reached en elevation
from eighteen to twenty feet above normal, it would be
nedessary, were the first method employed, to place the ap-
paratus at the extreme elevation to insure it from flood.

-~10-
This would necessitate lifting the water this height during
the greater portion of the year which, added to the necessary
discharge head and the friction of the long discharge line,
made it the least economical from an operating standpoint.
Again, isolated apparatus is liable to receive little atten-
tion and under such circumstances may become a source of
much expensive annoyance. To carry out the second method,
it would be necessary to sink a shaft in the power house to
a depth corresponding with low water in the river and by
means of a tunnel connect the latter with the former.
Pumps could then be placed in the shaft with their water ends
submerged and with their power ends, whether steam or elec
trical, located at such an elevation as to be overated from
the basement floor. This method would eliminate the suction
lift, the friction of a long discharge line, the cost ofr
the line and the pump house, and place the apparatus where
it could receive prover care without extra effort. If baro-
metric condensers were used this shaft would serve a second
purpose by affording space below ground for their discharge
legs, thereby materially reducing the height of the condenser
heads and consequently the lift of the condensing water.
Estimating the cost of installing the first
method, exclusive of the pumping apparatus, as $3000.00
and that of the second as $5000.00, the initial expenditure
favored the former, but when considered from an operating
standpoint, the latter was the more economical. The amount

—l1—
of water required to condense the steam from 2400 horse power
of ensines using fourteen pounds of steam per horse power
hour and thirty pounds of water per pound of steam would

equal 2400 x 14 x 30 or 16,800 pounds of water per minute.

 

60
By a reduction in head of twenty feet a saving of 16800 x 20
33000

or say ten horse power would be affected, which, at $25.00
per year, would equal $250.00 por year, considerable more
than the interest at five percent on the difference in first
cost and enough to warrant the construction of the shaft
and tunnel.

The use of barometric condensers, already
mentioned, had been considered from the start as they had
successfully served in the old plant. Experience there had
demonstrated them to be by far the best type for the service,
owing to their ability to operate with water containing
much foreign matter and scale producing constituents. A
surface condenser,with its numerous small tubes, would soon
become clogged with dead leaves or scale and rendered useless,
a condition calling for continual attention and expense to
Keep it in working order. With an almost inexhaustable
supply of water close by, jet condensers could be operated
without this trouble and the barometric type, owing to the
high lift and the absence of moving parts, would be the most
economical and simple to operate.

The electrical current in use in the old plant
was 220 volt, direct and was originally adopted on account

-12-
of the use of variable speed motors driving the rotary kilns
and the mine locomotive. While the use of direct current.
motors is unusual in modern ceinent plants, owing to the
gritty atmosphere in wiich they must operate, this Company
had gradually increased the amount of such apoaratus and,
strange though it may seem, their experisnce with it had
been entirely satisfactory. A record of maintenance ex-
pense had been carefully Kept covering a period extending
over several years and this failed to furnish any evidence to
their discredit. To discard the old motor equipment and re-
Place it with alternating current machines would mean the
sacrifice of a greater portion of its cost to say nothing

of the more serious loss in the time required for changing
over. The need for some direct current for the kiln motors
and the locomotive would still remain when the plant was re-
modeled and this, together with the loss involved were the
Old equipment replaced, were strong arguments in favor of con-
tinuing its use. The extra first cost of generators and
transmission line, using the low voltage direct current, was
thoroughly considered, out even this was not sufficient to
bring about the change.

The old engines, which were belted to jacx-
shafts, were indicated and the motors throughout the plant
tested to determine the power being used and to this was
added that necessary to operate the extra apparatus which
would be installed in the new arrangement.

-13-
TEST OF ENGINES.
Compound (Corliss)
Three Tube Mills
One Ball Mill
One Counter Snaft
Hlevators and Conveyors
Simple (Bates Corliss)

Three Tubs Mills
Counter Shaft

Elevators, belt driven from jacx-shaft,

Electrical Load, 950-1000 Amperes
Simple (Allis Corliss)
alectrical Load, 1100 Amperes

Total Full Load

TEST OF MOTORS.

 

 

Location Use Size H. P.
Coal House Coal Crusher 25
" Conveyor 15
" Dryer LO
" Speeder 6
" Elevator 5
Quarry Locomotive 40
Raw End Rock Crusher 75
" Belt 15
" Fan 10
" Conveyor 25
Grit Mills 125
Ball Mill 190
Blower Fan 10
#1 Kiln 10
#2 Kiln 10
#3 Kiln 10
#4 Kiln 10
#5 Kiln 10

—~14-

ee ee ee a

545 H.P.

554 H.P.

550 H.P.

 

1249 H.P.

Amperes

97.5
57.0
39.5
25.0
23.0

135.0

250.0
58.0
38.5
97.5

450.0

700.0
97.5
39.2
59.2
39.2
39.2

39.2

2262.5
TEST OF MOTORS (con't)

 

 

 

 

Location Use Size H.P. Aiperes
Brousht Forward 2262.5
Finish End Pan Conveyor 5 21.0
Clinker Pit Fan 10 38.0
Cooler Fan 35 153.0
Kent Mill 30 113.0
Kent Mill 30 113.0
Cément Belt 15 58.0
Sacking 5 21.0
sacking 5 21.9
sacking 5 21.0
sacking 5 21.0
Emery Wheel 6 21.0
2863.5
Lights 200.0
Total 3063.5

The requirements of the extra apvaratus

which was to be installed were as follows:

One Tube Nill in coal room 360 Amp.
Two #8 Ball Mills with Dryer and Elevator(raw end)350 "
Three 5 x 22 Tube Mills (raw end) 1080
Three 5 x 22 Tube Mills (finish end) 1800 "
Three Kent Mills (finish end) 480 "1
Extra Separators, Conveyors and Elevators 150 "*
Four Cooler Fans 480 +"
Sacking Motors 50 "
Uxtra power for Rock Crushers 100 "*
Extra lighting in Quarry and Mill 100 "
Total 4950"

Adding the total amperes obtained from the
individual motor readings to the total required by the extra
apperatus, we have 8013.5 amperes, which at 220 volts is
equal to 2363 H.P. Deducting the electrical load of 610

H.P. from the total of the enzine tests, wa have left a

—~15-
mechanical load of 639 H.P. Adding these results, we have
a total of 3002 H.P. By comparing the collective electrical
load as shown by the engine tests and the total of the in-
dividual readings, we find the collective load is about two—
thirds that of the total individual.

In view of the above, it was decided to pro-
vide 1800 electrical horse power in two equal units for the
first installation and arrange the building and auxiliary ap-—
paratus to care for an additional installation of 900 H.P.
As the load would be steady, large units, all of a size,
would make the best arrangement and with machines designed
to carry a fair overload, one unit could be temporarily shut
down if necessary.

The current was to be carried from the power
house to the mill on nine circuits arranged as follows:

800 Amperes to Coal Room.

600 " " Crushing House and Locomotive -
1000 " " Ball Mills.
1800 " Raw Grit Mills.

800 " " Rotary Kilns and Fan.

600 " " Kent Mills.
1800 " " Finish Grit Mills.

300 " " Sacking Platform.

300 " " Lights.

The lines supplying current for the raw grits,
rotary Kilns and fan were to be connected to the old switch-
board in the mill where the power would be divided and dis-—
tributed over the old circuits.

The boiler equipment was planned in the same
manner as the engines and divided into three batteries with

—~16-
 
two 400 H.P. boilers in each, making a total of 2400 H.P,,
1600 H.P. of which was to be installed at first. On account
of their being out of service more often for cleaning and the
requirements of the auxiliary apparatus for steam, the total
horse power of the boilers was made nearly equal to that of
the engines, although the latter would require but half the
steam that the former could produce.

Next came the matter of providing sufficient
draft for the boilers and,under ordinary circumstances, this
could best be accomplished with a chimney of moderate height.
In this case, however, it would be necessary to build a
chimney much higher than usually required to obtain the de-
sired unbalanced atmospheric conditions, owing to the proximi-
ty of the bluff. Induced draft was being employed in the old
plant for this purpose and as the apparatus was in first class
condition, it would answer for part of such an installation
in the new plant. The new apparatus could be installed first
and arranged to do the work until the old plant could be
dismantled and the old apparatus moved. If run with engines,
most of the heat in the steam would return to the boiler by
way of the heater so that the expense of operating it would
not be great and its first cost would be abcut half that of
a suitable chimney.

The use of economizers in connection with the
induced draft apparatus naturally sugzested itself as an
ideal arrangement from the standpoint of economy. Of course

—]7—
this point was solmewhat offset by the fact that there was
sufficient exhaust steam from the auxiliary apparatus to
heat all the boiler feed water. Again as the water was very
bad considerable trouble would doubtless be experienced in
the tubes. These facts coupled with the first cost of the
apparatus made the installation of economizers seem unwar-
ranted.

Samples of water taken from the river for

analysis were found to contain the following substances:

Silica 0.28 grains per gallon
Iron Oxide and Alumina 0.12 "of "
Calcium Sulphate 16.58 yo i"
Calcium Carbonate 2.04 n off i"
Magnesium Carbonate 10.81 a n
Sodium Sulphate 7.08 " of tt
Sodium Chloride 3.85 wt i"
Organic Matter 0.93 "oom i"

This analysis shows a large percentage of
sulphate which would not be separated from the water by
temperatures found in heaters, although a large portion of
the carbonate would doubtless be precipitated. To render
the water suitable for voiler feed purposes would require
the installation of chemical purifying apparatus and it was
possible to find such apparatus on the marxet, the makers
of which would guarantee its successful operation at the
nominal cost of two and one-half cents per thousand gallons
of water treated. <A heater could be arransed in conjunction
with the purifier and be supplied with exhaust steam from

the auxiliary apparatus in the plant.
—18-
It was planned to draw the wator for the
boilers from the condenser hot well and in this manner save
some of the heat contained in the engine exhaust. To render
this water suitable for the purpose, it would be necessary
to insert vacuum o1l separators in the exhaust connections
between the engines and condensers to extract the oil con-
tained in the steam. To lift the water from the hot well,
located about twenty feet below the basement floor level,
it was decided to use deep well pumps, the water end of
which would be submerged in the well and the steam end plac—
ed on the floor, the two being connected by wooden pump rods.

In order to suvpvly two sources of power to
operate the automatic stokers, an engine and motor were to
be installed. The latter, on account of the low cost of the
electrical power, would be used most of the tiie.

While the engins load would be quite steady
when once the new mill had settled down to a working basis,
there would necessarily be need for some adjustment before
this would be realized. The centrifugal pumps supplying
the condensers would operate steadily although furnished
with means for hand regulation and to take care of the
fluctuation between the amount of water required by the con-
densers and that supvlied by the pumps, storage tanxs were
to be installed on the ground level at one end of the plant
to act as a cushion. At the same time this storage of water
above the river would serve as a limited suvoly for the

-19
 
fire pump should anything oceur which would put the centri-
fugals out of service. In addition to these a 55,000 gal-
lon tank was to be placed on the highest point of the bluff
to be used as a gravity tank in connection with the fire pro-
tection system.

A cross compound steam driven compressor,
which supplied air to the rock drills in the mine, was to
be moved from the old plant, as was the duplex steam driven
pressure pump which supplied the mill with water. The form-
er was to be placed on the engine room floor while the lat-
ter would be placed in the basement and serve as a general
fire and service pump.

An electric hoist, hand traveled crane was
to be placed in the engine room to facilitate the erection
of the engines and generators and to handle such parts as
might be removed for repairs after the plant was in opera-—
tion.

Having settled upon the gensral type and
capacity of the pover equipment and laid out, in the rough,
the necessary water storage tanks, steam and water piping,
toilet facilities, sewerage and plumbing entering into the
make-up of a complete plant, it only remained to purchase
suitable apparatus, carefully plan its arrangement and pro-
perly install it in a substantial building to obtain a first
class and economical result.

The following spscifications were prepared

~20-
submitted to the respective makers of apparatus and pro-
posals solicited.
Boilers.

There shall be furnished four 400 H.P. water-—
tube boilers, delivered and erected on foundations built by
the Company, and left ready for brick work, steam and water
connections.

These boilers are to be set in two batteries
and arranged for mechanical stokers, which are to be furnish-—
ed under another contract.

The rating of the boilers shall be based on
an allowance of ten square feet of heating surface per horse
power.

With each boiler shall be furnished a pop
safety valve, set to blow at 150# pressure, one safety water
column cohnected, blow-off valve, one 12" pressure gauge,
and one set of firing tools. The contractor shall also
furnish one flue cleaner to be overated either by steam or
water.

Proposals shall state quality of steel used
in drums and tubes, number, thickness, size and riveting of
drums, number of fire and common brick necessary for setting
and dimensions of battery and single setting. The contrac-
tor shall furnish and put in place all special brick for
arches, baffles, etc. other than the fire and common brick

used in the setting.
—~2]-—
After the boilers are erected and before
brick work is comnenced they shall be tested and made tight
under a cold water hydrostatic test of 2004 per square inch
and a Hartford Steam Boiler Inspection and Insurance Company
policy for $500.00 shall be furnished for each boiler.
ENGINES.

There shall be furnished two engines which
shall be alike in all particulars. Each shall be horizon-
tal, cross compound, heavy duty type, arranged for overating
a continuous current generator direct connected. Bach shall
be of such size that when operated at a speed of 100 R.P.M.
with initial steam pressure of 150¢ and vacuum of 25" it will
develop 950 I.H.P. when cutting off at the most economical
point in the high pressure cylinder. Each snall be equipved
with double eccentrics to overate efficiently and satisfac—
torily through a wide range of loading. Disc cranks shall
be used. Each low pressure cylinder shall be arranged to
run on live steam indepencently cf the high pressure cylinder
during emergency requirements.

Proposals shall include for each engine a
quick acting throttle valve, drain valves, water relief
valves of ample capacity, a complete automatic pressure oiling
system, steam separator, metallic packing on piston rods and
valve stems, shields over cranks, three 12" gauges suitably
mounted and connected to indicate the pressure on high and
low pressure cylinders and the vacuum, all necessary wrenches,

~29—
and each cylinder shall be equipped with indicator connections
with three-way cocks. The low pressure piston shall be
babbetted. The inakes of separator, metallic packing and
gauges shall be approved by the consulting enzineer for the
purcnaser.

The engine builder will furnish the founda-
tion pnolts with nuts and square washers for the enzines and
deliver them at the purchaser's plant within twenty days from
date of contract.

The engine builder shall co-operate with the
pullder of the genorator and the consulting engineer regard-
ing the details of the engine and generator arrangements and
shall furnish the engineer blue prints promptly after such
arrangements shall have been azreed upon, the prints to show
fully the essential features of the apparatus including all
dimensions necessary for the desisn of the foundations and
the arrangement of pioing.

Proposals shall include with each engine a
re-nheater of ample and stated capacity, with all material
necessary to connect it to the cylinders. The purchaser will
furnish the necessary pioing to supply live steam to them and
for removing the condensation.

Material and workmanship shall be first
Class and proposals shall definitely specify what materials
are to be used and the character of the workmanship which

will be furnished under the contract and statethe following

—-23-
Diameter of cylinders and length of stroke.
Diamster, weight and width of fly-wheel.

Diameter and length of main bearings.

Diameter and length of cross head and crank pins.
Diameter of piston rods.

Size of connecting rods at center and near ends.
Bearing surface of cross head shoes.

Diameter of steam and exhaust pipes.

Weight of engine complete and floor space occupied.
Guaranteed steam consumption.

Guarantees on regulation.

The ensine builder will furnish the shafts,
base plates and either put the armatures upon the shafts or
deliver the shafts to the generator builder for that purpose.

Proposals shall include the services of an
expert erector to supervise the unloading, installating and
starting of the apparatus. The purchaser will furnish all
necessary foundations and ordinary labor for unloading and
erecting but in so doing will assume no responsibility for
the safety of the apparatus until it shall have been com-
pleted, started and accepted.

GENERATORS.

There shall be furnished two ganerators wnicn
shall be alixe in all particulars. Each of the two genera-—
tors will be approximately 700 K. W. capacity, direct driven,
continuous current, compound wound, operated at approximate-
ly 100 R.P.M. The full load voltage shall be about 250 and
the no load 220 volts.

Provosals are requested upon standard appara-
tus and shall include guarantees on efficiency, compounding,
overload capacity and heating, together with a statement of

~24—
 

 
the weight of each armature and commutator and total weight
of each generator.

The engine builder will furnish the shafts,
and either put the armatures uvon ths shafts or deliver the
shafts to the generator builder for that purpose. The
delivery is to be F.0.B. cars the vlant of the Marquette
Cement Manufacturing Company, via. the C.B. & Q Ry.

Proposals shall include the services of an ox-
pert erector to supervise the unloading, installating and
starting of the apparatus. The purchaser will furnish all
necessary foundations and ordinary labor for unloading and
erecting but in so doing will assume no responsibility for
the safety of the apparatus until it shall have been completed,
started and accepted.

SWITCHBOARD.

There shall be furnished, delivered and erected
One switchboard which shall consist of two generator and six
feeder panels. Each panel shall consist of two slabs of Biue
Vermont marble, free from flaws, the main one to be 62" hign
with sub-base 28" high. These are to be mounted on a suitable
angle iron frame work securely fastened to a cnannel iron
base with adjustable bracing rods to suoport board five feet
from the wall.

Connections on back of the board are to be
of hard drawn copper having a sectional area such that cur-
rent density will not exceed 800 amperes per square inch.

~25—
Bus—bars shall be laminated and provided heavy enough to taxe
care of three 750 K.W., 250 volt generators operating in
mnultiple. The third gensrator with its panels will be added
later. Current density for volted contacts must not exceed
200 amperes per square inch. All connecticns shall be furnish-
ed including suitable lugs for connecting feeder circuits. Ali
instrument connections to be run in straight horizontal and
vertical lines with right angle turns.

Proposals shall state the price per foot for
which the contractor will furnish the necessary lead cover-
ed pener insulated cable for connecting the generators to
the switchboard and between equalizer pedestals and shali in-
clude the labor for making th:se connections, the necessary
conduit or trenches to be furnished by the purchaser. The
size of the gensrator leads shall be 3,750,000 C.M., tne

field connections No. O, and the equalizer connections 2,000,

000 C.M.
The panels shal! ve as follows:

2 - Generator panels, each of 750 K.W. capacity, and upon each
of which shall be mounted,

1 - D.P. Independent arm, overload and reverse current, 3,000
anpere, I.T.E. circuit breaker.

1 - Type "Bt, illuminated dial, 4,500 ampere, Station Ameter.

1 - Rheostat ovoerating mechanism furnished by purcnaser.

1 — Greund detector push button.

1 -— Pilot lamp.

1 — Four point voltmeter receptacle and plug.

1 —- Tyve "G" Thomson Astatic recording wattmeter, 4,500

anpere cavacity mounted on sub—-base.

reeder pannel with
—- 1,800 ampere, auto-directite D.P., tandem non-closing
circuit breakers.

oO
|

—~26-
1 — Feeder panel with

1 - 1,000 and 1 — 800 ampere auto-directite D.P., tandem,
non closable circuit breakers.

l — Feeder panel with

1 —- 800 and 1 — 600 ampere auto-directite D.P., tanden,
non closable circuit breakers.

1 — Feeder panel with

l - 600 and 2 -— 300 ampere auto-directite D.P., tanden,
non closable circuit breakers.

2 - 2,000 ampere, quick break switches, each mounted on
separate cast iron pedestals, for
equalizer connection.

2 - 300 volt, tyne "B", iliuminated dial voltmeters mounted
on swinging bracket.

It is the intention of this specifications to
cover a complete switchboard, furnished, delivered and erect-
ed and connected to the generators ready to receive feeder
connections.

If the maxes of instruments and equipment
specified are deviated from in proposals, attention shall be
called to the substitutions with a full statement of those
offered.

INDUCED DRAFT APPARATUS.

There shall be furnished one induced draft
outfit with capacity for 2000 H.P. water tube boilers on the
basis of 5# of coal per horse power hour. It is proposed
to use an underground flue from the boilers to the fans,
which flue will be constructed under another contract and to
meet the requirements and conditions decided upon.

In the old power plant now in operation, a

—-27—
special 12' wheel 5' in width is in use. Proposals are re-
quested on installing the new apparatus complete with double
connection to the underground flue, removing the old appara-—
tus, with such reconstruction as will be necessary to meet
the new conditions, and connecting it to the new apparatus
in such a manner that either fan may be used at will. A
50! stack of ample size with double up—-take fitted with
dampers, for connecting to the fans shall be included, thus
making the final arrangement embody duplicate apparatus conm-—
plete in all parts.

The work shall be so handled that the new
apparatus may be put in use before the old is disturbed. It
is desired to get the nest and most compact arrangement
possible without obstructing or eliminating more of tne win-
dow area than necessary.

Proposals shall state fully what is offered,
together with a sketch of ths outfit, and guaranteed time
of completion of the new outfit and the re-arrangement of
the old.

BOILER FEHD PUMPS.

There shall be furnished and delivered two
duplex, outside end packed plunger pumps. They shall be
brass fitted and suitable for punping hot water for boiler
feed ourvoses.

The pumps shall be aliks in all particulars.
Each punp shall have a capacity of five galions per cycle of

—23-
both plungers. The steam pressure will be 1504 and the ex-
haust pressure 5 per square inch. They will be used for
feeding the boilers from which the steam is taken.

Companion flanses of suitable strength shall
be furnished on suction and discharge connections and with
eacn pump shall be furnished two sets of packing suitable
for hot water.

Proposals shall give the following information:

Diameter of cylinders and length of stroke.
Diameter of suction and discharge connections.
Details and arrangement of valves.

Space occupied by one pump.

The material and workmanship on these pumps
shall be first class and all parts of ample strength and so
designed as to safely meet the requirements. The proposals
shall definitely state and fully guarantee these features
CRANE.

There shall be furnished, delivered and erect—
ed on runway provided by the purcnaser, one twenty ton
electric hoist hand travel crane, equipped with trolley and
fitted with a direct current motor for hoisting with the
necessary devices and facilities for controlling it. cCur-
rent for the motor will be supplied by the purchaser at 220
to 240 volts. The trolley and bridge travel shall be operat-
ed by hand from the floor.

The conditions and requirements under which

the crane will operate are as follows:

~29—
span, c. tO c. runway rails. 54'O"

Distance frem floor to tov of rails. 27'oOn
Distance from too of rail to lowest point of

roof trusses. 5'gt
Distance from center of rails to inside of

walls. 10"
Distance from inside of walls to intersec-

tion of braces with roof trusses. 4'Q"
Distance from under side of roof trusses

to intersecticn of braces with walls. 5'Qn
Tcotel lift. 24'O"

While giving the essential features it is in-
tended thet the crane shall be of standard make and if
necessary some details of the building may be mocified to
that end.

The crane shall be given one coat of paint be-
fore leaving the shops of the maker and another coat after
erection of such color as may be iniicated by the purchaser.
Proposals shall einbody a full description of the crane of-
fered together with make of motor and such information as
may be necessary to indicate its type, speed and capacity.

It is expected that the building in which
the crane is to be installed will be ready to receive it
about March lst, and it is desired that the crane be erected
immediately following the completion of the building. The
power plent will be erected along the C.B. & Q Ry. with
side track to the building.

Provosals shall include price, date of
delivery and guarantees on the successful operation of the

crane in all particulars.

—~30—
8 oT tad eee A eX Pi -
PA ta Mea oN ed

i)

' A
a eS
ie Le a tn St

Pe nn es OS I ae
SN a ee Se

 
For the remainder of the apvsaratus, with the
exception of the piping, no specifications were prepared,
but a memorandum of requirements was furnished the respective
bidders who submitted proposals setting forth the details of
construction together with guarantees of performance and
efficiency.

After all proposals had bsen received, the
information contained therein was tabulated in form for a
comparative study of the various makes of apparatus submitted
and the capacities, size of parts, materials of construction,
weisnts and efficiency were cerefully considered.

In the case of the boilers, the general design,
heating surface, accessibility for cleaning and floor space
required were main factors in making a selection. In decid-—
ing upon the engines, the matter of general design, size of
eylindersa, materials used, size of bearings, pins and rods,
size and weight of fly-wheel, economy and regulation were of
most importance. The most important points in deciding the
selection of the generators, were the accessibility to
rotating parts, windings, efficiency and heating guarantees.

All of the auxiliary apparatus was considered
in the same manner and it may be superfluous to add that in
each case the matter of price was of no small importance.
Each of the items were weighed in conjunction with the price
for which the apparatus was offered and the selection made to
the end that the best equipment might be obtained for the

-—31—
least money.

iv is difficult to describe the many factors
entering into the selection of apvaratus so as not to leave
the impression that the engineer acts simply in the capacity
Of a purchasing agent, since the time has passed when he
designs all of the apparatus entering into the make-up of
a plant. The reputable concerns making standard apparatus
cannot, from a practical standpoint, change their designs to
suit every whim of the engineer, but at the same time minor
features can and often are altered to conform with what he
considers to be best for the work in hand. In this particular
case, it was found desirable to alter some features ofr the
selected apparatus,such as increasing the size of the ensine
crank shaft and pin bearings and to substitute a special type
of quick opening throttle valve for the one proposed. The
windings of the generators were changed to increase the over-—
load ratings and several minor points in the equipment of the
proposed switchboard were altered to improve its efficiency.

The final choice of boilers lay between two
makes, namely, the Babcock and Wilcox and the Stirling. These
peilers are of quite different types. The Babcock and Wilcox
has straight tubes with a hand hole and cover plate opposite
each end of each tube which has to be removed when the tubes
are cleaned, while the Stirling has tubes bent at the ends
ana all connected into drums with manholes in the ends. With
the former type, if the water is bad and the tubes have to be

—-32—
often cleaned, consideranie sxvense is involved in grinding
the seats of tne cover plates to maxe them tignt, while with
the latter all tubes can be cleaned with a turbine cleaner
from the inside of the drums with but three manholes to pack.
The Stirling type is a good steamer and in this instance, as
is often the case with its lowsr first cost due to the
smaller amount of labor necessary in its construction, there
seemed no real reason for paying ths additional price
necessary +o procure the Babcock and Wilcox boiler.

The equipment finally selected for this olant

consisted of ths following makes and sizes of apparatus:

4 — Stirling Company, 410 H.P. water-tube boilers with

4 — Green Ingineering Company chain grates.

2 — Fulton Iron Works, 1100 H.P., 22"x46"x48" heavy, cross
compound, condensing Corliss engines.

2 - Western Electric, 800 K.W.D.C.comp. wound generators.

1 —- Western Electric, eight panel switchboard.

1 -— B.F. Sturtevant Co., 240" three-quarter housed fan
direct connected to a 10" x 12"
horizontal engine.

1 —- Vater, 2400 H.P. heater and purifier.

2 - Fairbanks, Morse Company, 10" x 6" x 10" outside end
packed, pot valve, duplex feed puwnips.

2 - Hill, 6" x 30" deep well pumps.

2 —- Baragwanath, 18" barometric condensers.

2 - Lawrence Machine Company, 8" vertical submerged centri-
fugal punps direct connected to 50 H.P.
Jenney Electric vertical motors.

2-— Vater, 26" vacuum ofl separators.

1 - Whiting, 20 ton elsctric hoist hand travel crane.

Drawings of the selected apparatus, giving
the general outline, with dimensions and the location and de-
tails of all connections, were obtained from the builders
and the information incorporated into a general layout.

The building which resulted from this had one

—~ 5 Z—
working story with a basement and was divided into two main
parts, one to contain the voilers and their auxiliaries and
the other the vower gensrating equipment. <A one story addi-
tion, jcined to the main building at one end, was provided to
house the induced draft apvoaratus, the condenser punps with
their driving motors and the deep well pumps. The floor of
this part and that of the engine room basement were on the
same level. The floors of the boiler and enzine rooms were
placed at an elevation of fifteen feet above the rail of the
Burlington tracks. The whole area under the ensine room was
excavated, while under the boiler room only sufficient space
was provided for the cars ani the smoke flue. Steel ash
hoppers of about seven yards capacity were suspended from
the basement ceiling under the boilers and so arranged that
there was a clear height of ten feet above the rail.

The condenser heads were located in the en-
gine room about ten feet above the floor with their discharge
legs running along a trench in the basement and down the pump
shaft into the hot well. The reneaters, oil separators and
service pump were located in the basement under the engine
room, where also was placed bath and toilet facilities for
the plant operators. Most of the live steam and feed water
Piping was above the main floor while the exhaust connections,
blow-off and sewerage were in the basement.

The bottom of the pump shaft was fixed at
such an elevation as to insure a submergence of the pumps at

—~34—
low water periods which made it about forty feet below the.
pump house floor. The hot well, made of steel, was located
about half way down the shaft on a ledge formed by a contrac-—
tion in the size of the shaft. The shaft and the river were
connected by a tunnel of sufficient size to permit of a per-
son entering for the purpose of cleaning it out. The overflow
from the hot well was carried dovm the shaft in an iron pipe
and thence thrcugh tile laid along the side of the tunnel to
the river on the down stream side of the intake. As the
river water contained a large amount of floating material
which might clog the apparatus, a gate house was placed on
the river end of the tunnel to control the inlet. This house
was divided into two duplicate compartments fitted with gates
and screens and connected by a third to the tunnel. By
closing the outer and inner gates of one compartment, its
screens could be removed for cleaning without shutting off
the water supply to the plant. The operating floor was lo-
catod above the high wetsr so that the inlet would be under
control at all times. The shaft, gate house and tunnel were
all to be constructed with concrete walls. Owing to the
peculiar shifting of the bore for the tunnel during excava-
tion, it was found necessary to abandond the use of concrete
in its construction.

When the general layout has been completed and
the amount of space required determined, detail plans were
prepared for the building, machinery foundations, pump shaft,

— 35—
if rable
BI bane

JIM

 
tunnel, gate house and piping.

The building was to be constructed of non-
combustible materials as far as practicable, Keeping in mind
the advantage of using cement as an advertising feature. To
this end, the building was planned with the lower portion,
from the ground to the main floor, of concrete; the walls of
brick with the joints left unstruck to receive a cover of
rought cement plaster; the main floor of stone concrete rein-
forced and the roof of cinder concrete reinforced. The roof
and crane runway were suovoorted on a steel frame work, leav-—
ing the wooden doors, window sash and frames the only conm-—
bustible in the whole construction.

The lower portion of the building, being in
reality its foundations, was massive enough to permit of con-
crete being economically used in its construction, while the
walls above the main floor were so cut up with large openings
for windows and doors that the extra cost of the forms for
concrete made their construction of brick much cheaper, and
when coated with plaster would not only present a pleasing ap-
pearance but carry out the cement plan. For floors and roof,
nothing would so well meet the requirements as concrete.

The detail designing of the building began at
the top or roof. First it must be covered with a waterproof
roofing, as the concrete itself would not be impervious and
would cause a great amount of annoyance by sweating underneath

if not protected on the outside. <A thorough canvass of the

—~3G6—
various materials used for this purpose was made with a view
to their durability and first cost with the result that a
composition roof made of asphalt, felt and cravel was select-—
ed.

The steel work was laid out with a view to-
wards the economical distribution of the material and the
detail plans submitted to bidders with the following speci-
fications.

Proposals are requested for furnishing,
delivering and erecting all steel work shown on drawing #3,
which accompanies and forms a part of this specification.
Provosals shall contemplate the execution of the work accord-
ing to the details and to meet the requirements shown. If
the details shown on the plans are deviated from or other
sizes of material used, the allowable unit compressive
stress is to be 16000 ee lbs. per square inch and the
tension stress 15000 lbs per square inch, and no metal of
less thickness than 1/4" shall be used except for fillers,
and no angles less than 2 1/2" xX 2" x 1/4". Rivets shall be
go spaced and of such size that the shearing stress shall
not exceed 10000 lbs. per square inch or the bearing value
20000 lbs.

Field rivets shall be spaced for stresses two-
thirds of those allowed for shop rivets and field bolts are
to be spaced for stresses two-thirds of those allowed for
field rivets.

—37—
All steel shall be of such quality as to meet
the Manufacturers Standard Specifications for mediw structur-
al steel. All riveting is to be well done with the holes
true, well filled and the heads well formed concentric with
the noles. Where several pieces are brought together they
must fit closely and when riveted shall be free from twists,
bends or oosn joints. All surfaces in contact shall be
painted before they are put together and before leaving the
shop the material shall be thoroughly cleaned of all loose
scale and rust and given one coat of pure boiled linseed oil.
After erection tho work shall be given a coat of PitkKin's
Graphite Red Lead or Detroit Superior Graphite paint of such
color as may be selected.

the contractor shall furnish at his own ex-
pense, all necessary tools, staging and material required for
ths erection of the work and remove the same when the worx
is completed. The contractor shall assume all risks from
storms or accident until the worx is completed and accepted.

In planning the piping layout, safety and
economy in operation were the results to be obtained and to
this end all of the high pressure steam and water lines
were made up with full weicht pipe and extra heavy fittings.
The pipe and fittings used for the low pressure steam and
water were of standard weight, except the exhausts from the
condenser relief and heater back pressure valves which were
made of spiral riveted galvanized iron pipe and malleable

_~38-
fittings. Each boiler was connected to the twelve inch head-
er with an eight inch goose neck to insure dry steam and a
globe valve was placed in each connecticn at the header. An
automatic non-return valve was located on top of the boiler
to protect the men when it was being cleaned or in case of
accident to it. The connections to the ensines, compressor
and auxiliary apparatus were taxen off the top of the header
and each, in additon to the throttle valve, had a globe or
angle valve at the header.

All the header valves six inches and larger
were by-passed and the header and all low points in the pip-
ing were drained with traps of amole size.

To further insure the reciprocating apparatus
against damazse from water, large receiver separators were
provided for each unit. These also were drained by traps.

All of the piping was laid out, supported and
the connections made in such a manner that no undue strains
would be caused by expansion.

A fourteen incn discharge line from the centri-
fugal pumps ran through the basement of the power house and
just back of the condenser legs to the storage tanks outside.
The condensers were so located that their throats were eight
feet above the mean level of the water in the tanks and each
was supplied from the pump discharge line by a seven inch
connection carried up to the inlet just above the throat. The
discharge legs from the condenser were carried down along side

—39-
of the supply pipes,thence inthe trencn to the hot well in the
pump shaft. At a point below the normal water level in the
tanks, a by-pass was connected across from the injection
supply pipe to the discharge leg and a valve placed in it and
in the supply pipe above the cross connection. This arrange-
ment was adopted in order that the condensers could draw
their supply when in full operation and at the same time pro-
vide a means for starting them when the encines were put in
run. In starting up an engine, the sxhaust steam could
escape through the relief valve to the atmosphere and the
engine run non-condensing. The valve in the supply line be-
ing closed, that in the by-pass would be opened and the water
flowing down the drop leg would form a partial vacuum which
would draw over some exhaust steam. The condensation of this
steam would increase the vacuum sufficiently to raise the
water in the injection pipe when its valve was opened. After
the supply nad reached the head of the condenser, the by-
pass would be closed forcing all of the water through the
head.

The flange joints in the high pressure steam
lines and in the connections between engines and condensers
were to be made up by screwing the pipe through the flange
and peening it in,. then facing off the pipe and flange to-
gether. All other flanged joints were made in the same man-
ner with the omission of the peaning. All piping three

inches and above was to have flanged joints, all under that

~40—
‘tobe?

ly 7
e AQ
eg

 
size to be made up with couplings and unions.

All steam valves except for some of the exhaust
lines were to be slobe or angle and those in the water lines
were to be gate. All flanged valves were to be iron body,
bronze fitted and all screwed valves were to be bronze
throughout. The valves on the header and those used as
throttles on the auxiliary apparatus were to be of the "Crosby"
make, the automatic non-return valves "Foster" and the re-
maining ones "Crane Company". "Jenkins "96" gaskets, which
are rubber treated with graphite, were to be used in all
live steam and high pressure hot water lines and "Rainoow"
(rubber) on the exhaust and low pressure water lines.

The high pressure steam piping was to be
covered with H. W. Johns-—Manville Company's asbestos sponge
felt and the exhaust steam and hot water piping was to be
covered with one inch asbestos air cell. A two inch cover-
ing of asbestos sponge felt was to be applied to the steam
separators and the heater was to be covered with magnesia
blocks two inches thick.

In general, the artificial lighting of the
plant was to be done with are lamps, incandescents being
used in the basement, car tunnel and around the pumps and
fans. A cabinet box was located in the engine room near one
of the doors leading to the boiler room and from this box
circuits were run in conduits to the motors around the power

house and to the lichts. Each are was on an individual

—~41-
circuits while the incandescents were grouped.

Each generator was connected to the switch-—
board by rubber covered cables, supvorted from the steel
beams on the ceiling of the basement by "Fletcher" porcelain
clams in iron frames. The cross section of one cable suf-
ficient to carry the current would be too large for con-
venient handling,so three cables, 1,250,000 C.M. each,were
used for each line, their ends being joined at the generator
and switchboard by a specially designed clamp.

The cables for carrying the current to the
mill were made up of soft drawn stranded copper wires cover-
ed with three closely woven braids of jute, thoroughly in-
pregnated with a high grade of waterproof compound. These
cables were strung on wooden supvorts made up of two — forty-
five foot cedar poles, set seven feet apart and connected
with four double sets of 6" x 4" yellow pine cross arms,
securely bolted and braced to the poles. One and one-half
inch oak pins set in tandem were spaced twelve inches apart
on the cross arms and each carried a #3 Knowles glass insula-
tor on which the cables rested. The supvorts were spaced
one hundred feet apart and thoroughly braced with strand-
ed galvanized iron guy wires.

The first installation of cable consisted
of four circuits run as follows: To the old switchboard, two
1,250,000 C.M. cables; to the crusher house, two 850,000 C.N.
cables; to the raw end one 1,250,000 C.M. cable and to the

-—-423—-
finishing end, one 850,000 C.M. cable.

It wes the intention of the Company to let all
work of construction to contractors, but owing to the ex-
tremely high figures covering some features, principally the
excavation, tunnel and foundations, due ne doubt to a large
element of uncertainty, and the Company's desire to push the
work with all possible speed, they finally decided to carry
on as much of the construction as vossible themselves.

The site which had been closen for the build-
ing had a very irregular surface covered with trees, under-
brush and large boulders. The latter were originally a part
of the bluff, but had become loosened by the elements and
broken away. To reduce this area to the required level was
an arduous task requiring the removal of approximately
ten thousand cubic yards of material and to loosen both
rock and earth, blasting was resorted to throughout the work
of excavation. The material was shoveled into dump cars by
laborers and hauled away and deposited on the low ground
along the river bank.

The foundations of the building had been de-
signed for a bearing value determined by average conditions,
but when the excavation had been completed, it was found
that they would have to be redesigned to make allowance for
the wide ranse of soil conditions,which in a width of one
hundred feet, varied from a firm hard rock to a black loam.

Durins the exeavation for the building

—-43—
aerial laa” |
he ct So ay
a

 
foundations, work was started on the pump shaft and tunnel,
the latter being worked from each end. A working shaft about
seven feet square cribbed with plank and timber was sunk
near the river just back from tne provosed location of the
gate house, a hand winch was olaced over the opening for
hauling up the buckets of excavated material and a pulsomster
was used to Keep the wcrk free from water. The work at the
river progressed much faster than that at the pump shaft
Owing to the smaller size of the bore and the lesser amount
of care necessary in its excavation. As soon as the desired
depth had been reached, a drift was started from each end
towards the center, the work of excavation being followed

by timber shoring. A narrow gaure track was laid on the
bottom of the tunnel on which to run a small flat car which
was used to carry the buckets between the head of the drift
and the hoisting shaft.

In order to prevent undue settling in the
surrounding soil, the sinking of the pump shaft had to be
done with great care. The excavation was carried down in
steps of no greater depth than that which would leave the
earth walls standing intact. That much of the concrete wall
of the finished shaft was then built and after sufficient
time had been allowed for it to set, the forms were remov-
ed and another section excavated. In this manner the re-
quired depth was reached without disturbing the surround-
ing soil. The material encountered in the excavation

-44-
of the shafts and tunnel was principally clay, although

a flat ledge of rock was found near the bottom of the pump
shaft, which extended some ten or fifteen feet into the
tunnel. When it was found necessary to abandon the construc-—
tion of a concrete tunnel, a 36" cast iron pipe was sub-
stituted and owing to the difficulty of handling this heavy
pipe in the restricted space if furnished in the usual
tvelve foot lengths, six foot lengths were procured. These
were lowered down the shafts and skidded along the tunnel

on rollers into place. All of the joints were leaded and
caulked, the 18" tile line for the overflow laid along side,
and then the earth backfilling thoroughly tamped around botnh.
When all of the pipe was in place, the shaft at the river
was filled up.

Next came the construction of the gate house.
In order to build this, it was necessary to Keep the water
back with a coffer damp which was done by means of a double
wall dan of heavy planking, built in the form of a V with
the apex pointing out into the river and the two legs run-
ning into the bank. The space between the walls was filled
and puddled, and earth from the gate house excavation was
banked up around the outside.

When the foundations for the building and
machinery had been completed, the steel contractor was call-
ed upon to start the erection of the building frame work and
the floor beams. After these were in place, the crane was

~45—
 

 

erected and the plant made ready to receive its first in-
stallation of inachinery.

The supvoorting frame for the boilers was the
first item to be installed, after which the boilers them-
selves were erected and their brick work carried along with
.thet of tne pbuilding.

The erection of the engines followed along
in the course of a short time, some parts, however, being
left until the roof had been completed.

A contract had been made for the concrete
floor and roof and the roof was started as scon as the steel
work was in place. In designing this roof it was so ar-
ranged that the underside would be flat and rest on the t@
of the purlins, being anchored to them with clips. This
made the forming very simple as the planking would extend
from the edge of one purlin to that of another and could
be supported by joists resting on their lower flanges. Lit-
tle cutting or nailing being necessary, the forms could be
easily and quickly erected or removed. The forms were left
on for a ccuple of days, after which the concrete was
sufficiently strong to permit of their removal. The work
was carried on in sections and the same forms used several
times.

After the enzine room had been covered, the
generators and switchboard were erected and in the meantime
the auxiliary apparatus had been installed. The plant was

-~46—
 
 
now ready for connecting up and the piping, which had al-.
ready been contracted for and delivered, was put in place.
All of the large piping down to and including six inch, was
maus up with flanges and fittings in the shop where ordered,
closins-in pieces being left for final measurements on the
Job. The cutting and fitting of the smaller sizes and the
erection of the whole job was dione by the Company's own men
uncer the supervision of a competent foreman, who furnished
the necessary tools with his services on a per diem basis.

The connections between the senerators and
switchboard were made and the power house wired for power
anc light, this being followed by tne construction of the
transmission line to the mill.

the sewer from the plant was run across the
tracks and down to the river on the down stream side of the
gate house and an 8" water line was carried from the fire
punop in the basement to the gravity tank on the nill and con-
nections made to the mill and the warehouse on the bluff.

With the finishing touches, such as roof
covering, sheet metal worx and interior trim finished, the
plant was ready to be put in run and the opportunity had
arrived for determining whether or not it was a success
and would result in the saving expected.

From the start the plant overated without a
hiteh and in a short tine following the completion of the
re-arranged mill, it was deiionstrated that it could overate

—-47
economically under an exceedingly heavy overload.

In conclusion, is siven the itemized cost of
the new plant, the cost of operating it and the old one
each for a period of one year and the amount cf cement pro-
duced in the respective periods.

COST OF PLANT.

Building $41,692
Gate House, Tunnel and Well 3,575
Boilers and Flue 14,772
stokers 4,800
Coal Chutes and Ash Hoppers 1,701
Induced Draft Apparatus (old $1,050) 3,897
Deep Well Pumps 641
Boller Feed Pumps 750
Heater and Purifier 2,950
Engines 25,500
Generators 20,020
Switchboard and Generator Cable 7,550
Condensers 1,000
Centrifugal Pumps and Motors 2,450
Storage Tanks 1,254
Oil Separators 1,100
Piping including cast iron 12,500
Crane 2,750
Pole Line and Lighting 11,029
Trestle 1,000
Miscellaneous moving and erection 4,500

 

Total Original Installation $165,431
Adding $41,235, the cost of the third unit
including two boilers, one engine and generator with their
appurtenances, another centrifugal pump and motor and the
necessary piping and cable for connecting them with the
first installation, we have a total cost of $206,666, making
the cost per horse power $68.89
Below is the operating expense of the old
power plant in 1905 and that of the new one in 1907.
—4g8—
OPERATING EXPENSE.

1905 1907
Labor $19,700 $14,900
supplies 298 321
Coal 33,773 38,000
O11 1,373 1,990
Repairs 12,576 4,560

Total $67,720 $59,771

Comparing these figures and considering that
with the old plant there was produced not to exceed
500,000 barrels of cement per year while the present yearly
output is about 1,000,000 barrels it becomes evident that
the Company is saving a trifle over six cents per barrel in
the cost of power alone.

The above gives ample proof that the building
of this plant was warranted and that its location and ar-

rangement were large factors in bringing about the results.

~49-
 
 

 

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