HOW TO USE THE TEST RESULTS.

The object of working up a test is to obtain a clear idea as to the efficiency of operation of the boiler or its operating cost. Consequently, after the calculations have been made, they should be used as a basis for study with the idea of improving the boiler performance.

Take the matter of boiler efficiency, for example, as found from the test mentioned. Its value was 54 per cent. This is altogether too low and indicates wasteful operation. The efficiency of a hand-fired boiler ought not to be less than 65 per cent, and it can be increased to 70 per cent by careful management under good conditions.

The chart in figure 3 can be used to indicate the evaporation that should be obtained in order to reach a desired efficiency. Suppose, for example, that it is desired to know how much water per pound of coal must be evaporated to produce a boiler efficiency of 65 per cent with coal having a heating value of 13,500 B. t. u. per pound.

Locate 13,500 at the bottom of the chart, follow the vertical line until it meets the diagonal marked 65 per cent, and then from this point follow the horizontal line to the left-hand edge, where the figure 9 is found. This means that the equivalent evaporation from and by 212° F. per pound of coal must be 9 pounds of water. If the steam pressure is 100 pounds gauge, and the feed-water temperature is 180° F. the factor of evaporation is 1.0727, then the actual evaporation must be 9 ÷ 1.0727 = 8.36 pounds per pound of coal. In other words, to increase the efficiency from 54 per cent to 65 per cent under the same conditions of pressure and feed-water temperature, it would be necessary to increase the actual evaporation from 7 pounds to 8.36 pounds. This would mean practically 20 per cent more steam from the same weight of coal used.

How to do this will require some study and experimenting on the part of the fireman or engineer. The three most common reasons for low-boiler efficiency are (1) excess air, (2) dirty heating surfaces, and (3) loss of coal through the grates. The first of these items is the most important of the three. In most cases the greatest preventable waste of coal in a boiler plant is directly due to excess air. Excess air simply means the amount of air which gets into the furnace and boiler which is not needed for completing the combustion of the coal. Very often twice as much air is admitted to the boiler setting as is required. This extra or excess air is heated and carries heat out through the chimney instead of heating the water in the boiler to make steam. There are two ways in which this excess air gets into the furnace and boiler setting. First, by a combination of bad regulation of drafts and firing. The chances are your uptake damper is too wide open. Try closing it a little. Then, there may be holes in the fire. Keep these covered. The second way excess air occurs is by leakage through the boiler setting, through cracks in the brickwork, leaks around the frames and edges of cleaning doors, and holes around the blow-off pipes. There are also other places where such air can leak in.

Take a torch or candle and go over the entire surface of your boiler setting—front, back, sides, and top. Where the flame of the torch is drawn inward there is an air leak. Plaster up all air leaks and repair the brickwork around door frames where necessary. You should go over your boiler for air leaks once a month.

In regard to best methods of firing soft coal, see [Technical Paper No. 80] of the Bureau of Mines, which may be obtained from your State Fuel Administrator.

Dirty heating surfaces cause low efficiency because they prevent the heat in the hot gases from getting through into the water. Therefore, keep the shell and tubes free of soot on one side and scale on the other. Soot may be removed by the daily use of blowers, scrapers, and cleaners. The problem of scale and pure feed water is a big one and should be taken up with proper authorities on the subject.

There are many things that may be done to increase the efficiency of the boiler and to save coal. For convenience a number of these points are grouped in the following list:

WHAT TO DO.WHY.
1. Close up all leaks in the boiler setting. To prevent waste of heat due to excess air admitted.
2. Keep shell and tubes free from soot and scale. To allow the heat to pass easily into the water.
3. Use grates suited to the fuel to be burned. To prevent loss of unburnt coal through air spaces.
4. Fire often, and little at a time. To obtain uniform conditions and better combustion.
5. Cover all thin spots and keep fire bed level. To prevent burning holes in bed and admitting excess air.
6. Do not allow clinkers to form on side or bridge walls. Because they reduce the effective area of the grate.
7. Keep the ash pit free from ashes and hot clinkers. To prevent warping and burning out of the grates.
8. Do not stir the fire except when necessary. Because stirring causes clinker and is likely to waste coal.
9. Use damper and not ash-pit doors to control draft. Because less excess air is admitted by so doing.
10. See that steam pipes and valves are tight. Because steam leaks waste heat and therefore coal.
11. Keep blow-off valves tight. Because leaks of hot water waste coal.
12. Cover steam pipes and the tops of boilers. To prevent radiation and loss of heat.

Make a boiler test under the conditions of operation as they now exist in your plant. Then make all possible improvements as suggested in this bulletin, make another test afterwards and note the increase in the equivalent evaporation per pound of coal used.

Remember that the firing line in the boiler room can be just as patriotic and helpful as the firing line at the front.

Table of factors of evaporation.

Feed
temperature,
Steam pressure in pounds per square inch, gauge.
°F. 30 50 70 80 90 100 110 120
32....... 1.2073 1.2144 1.2195 1.2216 1.2234 1.2251 1.2266 1.2279
35....... 1.2042 1.2113 1.2164 1.2184 1.2203 1.2219 1.2235 1.2248
38....... 1.2011 1.2082 1.2133 1.2153 1.2172 1.2188 1.2204 1.2217
41....... 1.1980 1.2051 1.2102 1.2122 1.2141 1.2157 1.2173 1.2186
44....... 1.1949 1.2020 1.2071 1.2091 1.2110 1.2126 1.2142 1.2155
47....... 1.1918 1.1989 1.2040 1.2060 1.2079 1.2095 1.2111 1.2124
50....... 1.1887 1.1958 1.2009 1.2029 1.2048 1.2064 1.2080 1.2093
53....... 1.1856 1.1927 1.1978 1.1998 1.2017 1.2033 1.2049 1.2062
56....... 1.1825 1.1896 1.1947 1.1967 1.1986 1.2002 1.2018 1.2031
59....... 1.1794 1.1865 1.1916 1.1937 1.1955 1.1972 1.1987 1.2000
62....... 1.1763 1.1835 1.1885 1.1906 1.1924 1.1941 1.1956 1.1970
65....... 1.1733 1.1804 1.1854 1.1875 1.1893 1.1910 1.1925 1.1939
68....... 1.1702 1.1773 1.1823 1.1844 1.1862 1.1879 1.1894 1.1908
71....... 1.1671 1.1742 1.1792 1.1813 1.1832 1.1848 1.1864 1.1877
74....... 1.1640 1.1711 1.1762 1.1782 1.1801 1.1817 1.1833 1.1846
77....... 1.1609 1.1680 1.1731 1.1751 1.1770 1.1786 1.1802 1.1815
80....... 1.1578 1.1650 1.1700 1.1721 1.1739 1.1756 1.1771 1.1785
83....... 1.1548 1.1619 1.1669 1.1690 1.1708 1.1725 1.1740 1.1754
86....... 1.1518 1.1588 1.1638 1.1659 1.1678 1.1694 1.1710 1.1723
89....... 1.1486 1.1557 1.1608 1.1628 1.1647 1.1663 1.1679 1.1692
92....... 1.1455 1.1526 1.1577 1.1597 1.1616 1.1632 1.1648 1.1661
95....... 1.1424 1.1495 1.1546 1.1566 1.1585 1.1602 1.1617 1.1630
98....... 1.1393 1.1465 1.1515 1.1536 1.1554 1.1571 1.1586 1.1600
101....... 1.1363 1.1434 1.1484 1.1505 1.1523 1.1540 1.1555 1.1569
104....... 1.1332 1.1403 1.1453 1.1474 1.1492 1.1509 1.1525 1.1538
107....... 1.1301 1.1372 1.1423 1.1443 1.1462 1.1478 1.1494 1.1507
110....... 1.1270 1.1341 1.1392 1.1412 1.1431 1.1447 1.1463 1.1476
113....... 1.1239 1.1310 1.1360 1.1382 1.1400 1.1417 1.1432 1.1445
116....... 1.1209 1.1280 1.1330 1.1351 1.1369 1.1386 1.1401 1.1415
119....... 1.1178 1.1249 1.1299 1.1320 1.1339 1.1355 1.1370 1.1384
122....... 1.1147 1.1218 1.1269 1.1289 1.1308 1.1324 1.1340 1.1353
125....... 1.1116 1.1187 1.1238 1.1258 1.1277 1.1293 1.1309 1.1322
128....... 1.1085 1.1156 1.1207 1.1227 1.1246 1.1262 1.1278 1.1291
131....... 1.1054 1.1125 1.1176 1.1197 1.1215 1.1232 1.1247 1.1260
134....... 1.1023 1.1095 1.1145 1.1166 1.1184 1.1201 1.1216 1.1230
137....... 1.0993 1.1064 1.1114 1.1135 1.1153 1.1170 1.1185 1.1199
140....... 1.0962 1.1033 1.1083 1.1104 1.1123 1.1139 1.1154 1.1168
143....... 1.0931 1.1002 1.1052 1.1073 1.1092 1.1108 1.1124 1.1137
146....... 1.0900 1.0971 1.1022 1.1042 1.1061 1.1077 1.1093 1.1106
149....... 1.0869 1.0940 1.0991 1.1011 1.1030 1.1046 1.1062 1.1075
152....... 1.0838 1.0909 1.0960 1.0980 1.0999 1.1015 1.1031 1.1044
155....... 1.0807 1.0878 1.0929 1.0950 1.0968 1.0985 1.1000 1.1013
158....... 1.0776 1.0847 1.0898 1.0919 1.0937 1.0954 1.0969 1.0982
161....... 1.0745 1.0817 1.0867 1.0888 1.0906 1.0923 1.0938 1.0952
164....... 1.0715 1.0786 1.0836 1.0857 1.0875 1.0892 1.0907 1.0921
167....... 1.0684 1.0755 1.0805 1.0826 1.0844 1.0861 1.0876 1.0890
170....... 1.0653 1.0724 1.0774 1.0795 1.0813 1.0830 1.0845 1.0859
172....... 1.0632 1.0703 1.0754 1.0774 1.0793 1.0809 1.0825 1.0838
174....... 1.0611 1.0683 1.0733 1.0754 1.0772 1.0789 1.0804 1.0817
176....... 1.0591 1.0662 1.0712 1.0733 1.0752 1.0768 1.0783 1.0797
178....... 1.0570 1.0641 1.0692 1.0712 1.0731 1.0747 1.0763 1.0776
180....... 1.0549 1.0621 1.0671 1.0692 1.0710 1.0727 1.0742 1.0756
182....... 1.0529 1.0600 1.0650 1.0671 1.0690 1.0706 1.0721 1.0735
184....... 1.0508 1.0579 1.0630 1.0650 1.0669 1.0685 1.0701 1.0714
186....... 1.0488 1.0559 1.0609 1.0630 1.0648 1.0665 1.0680 1.0694
188....... 1.0467 1.0538 1.0588 1.0609 1.0628 1.0644 1.0660 1.0673
190....... 1.0446 1.0517 1.0568 1.0588 1.0607 1.0623 1.0639 1.0652
192....... 1.0425 1.0497 1.0547 1.0568 1.0586 1.0603 1.0618 1.0632
194....... 1.0405 1.0476 1.0526 1.0547 1.0566 1.0582 1.0597 1.0611
196....... 1.0384 1.0455 1.0506 1.0526 1.0545 1.0561 1.0577 1.0590
198....... 1.0363 1.0435 1.0485 1.0506 1.0524 1.0541 1.0556 1.0570
200....... 1.0343 1.0414 1.0464 1.0485 1.0504 1.0520 1.0535 1.0549
202....... 1.0322 1.0393 1.0444 1.0464 1.0483 1.0499 1.0515 1.0528
204....... 1.0301 1.0372 1.0423 1.0444 1.0462 1.0479 1.0494 1.0507
206....... 1.0281 1.0352 1.0402 1.0423 1.0441 1.0458 1.0473 1.0487
208....... 1.0260 1.0331 1.0381 1.0402 1.0421 1.0437 1.0453 1.0466
210....... 1.0239 1.0310 1.0361 1.0381 1.0400 1.0416 1.0432 1.0445
212....... 1.0218 1.0290 1.0340 1.0361 1.0379 1.0396 1.0411 1.0425

Table of factors of evaporation—Concluded.

Feed
temperature,
Steam pressure in pounds per square inch, gauge.
°F. 130 140 150 160 170 180 190 200
32....... 1.2292 1.2304 1.2315 1.2324 1.2333 1.2342 1.2351 1.2358
35....... 1.2261 1.2273 1.2283 1.2293 1.2302 1.2311 1.2320 1.2327
38....... 1.2230 1.2242 1.2252 1.2262 1.2271 1.2280 1.2288 1.2296
41....... 1.2199 1.2211 1.2221 1.2231 1.2240 1.2249 1.2257 1.2265
44....... 1.2168 1.2180 1.2190 1.2200 1.2209 1.2218 1.2226 1.2234
47....... 1.2137 1.2149 1.2159 1.2168 1.2178 1.2187 1.2195 1.2202
50....... 1.2106 1.2118 1.2128 1.2137 1.2147 1.2156 1.2164 1.2171
53....... 1.2075 1.2087 1.2097 1.2107 1.2116 1.2125 1.2133 1.2141
56....... 1.2044 1.2056 1.2066 1.2076 1.2085 1.2094 1.2102 1.2110
59....... 1.2013 1.2025 1.2035 1.2045 1.2054 1.2063 1.2072 1.2079
62....... 1.1982 1.1994 1.2005 1.2014 1.2023 1.2032 1.2041 1.2048
65....... 1.1951 1.1963 1.1974 1.1983 1.1992 1.2002 1.2010 1.2017
68....... 1.1920 1.1933 1.1943 1.1952 1.1961 1.1971 1.1979 1.1986
71....... 1.1889 1.1902 1.1912 1.1921 1.1931 1.1940 1.1948 1.1955
74....... 1.1859 1.1871 1.1881 1.1890 1.1900 1.1909 1.1917 1.1924
77....... 1.1828 1.1840 1.1850 1.1860 1.1869 1.1878 1.1886 1.1894
80....... 1.1797 1.1809 1.1820 1.1829 1.1838 1.1847 1.1856 1.1863
83....... 1.1766 1.1778 1.1789 1.1798 1.1807 1.1817 1.1825 1.1832
86....... 1.1735 1.1748 1.1758 1.1767 1.1776 1.1786 1.1794 1.1801
89....... 1.1704 1.1717 1.1727 1.1736 1.1746 1.1755 1.1763 1.1770
92....... 1.1674 1.1686 1.1696 1.1705 1.1715 1.1724 1.1732 1.1739
95....... 1.1643 1.1655 1.1665 1.1675 1.1684 1.1693 1.1701 1.1709
98....... 1.1612 1.1624 1.1635 1.1644 1.1653 1.1662 1.1671 1.1678
101....... 1.1581 1.1593 1.1604 1.1613 1.1622 1.1632 1.1640 1.1647
104....... 1.1550 1.1563 1.1573 1.1582 1.1592 1.1601 1.1609 1.1616
107....... 1.1519 1.1532 1.1542 1.1551 1.1561 1.1570 1.1578 1.1585
110....... 1.1489 1.1501 1.1511 1.1521 1.1530 1.1539 1.1547 1.1555
113....... 1.1458 1.1470 1.1481 1.1490 1.1499 1.1508 1.1515 1.1524
116....... 1.1427 1.1439 1.1450 1.1459 1.1468 1.1478 1.1486 1.1493
119....... 1.1396 1.1409 1.1419 1.1428 1.1437 1.1447 1.1455 1.1462
122....... 1.1365 1.1378 1.1388 1.1397 1.1407 1.1416 1.1424 1.1431
125....... 1.1335 1.1347 1.1357 1.1366 1.1376 1.1385 1.1393 1.1400
128....... 1.1304 1.1316 1.1326 1.1336 1.1345 1.1354 1.1362 1.1370
131....... 1.1273 1.1285 1.1295 1.1305 1.1314 1.1323 1.1332 1.1339
134....... 1.1242 1.1254 1.1265 1.1274 1.1283 1.1292 1.1301 1.1308
137....... 1.1211 1.1224 1.1234 1.1243 1.1252 1.1262 1.1270 1.1277
140....... 1.1180 1.1193 1.1203 1.1212 1.1221 1.1231 1.1239 1.1246
143....... 1.1149 1.1162 1.1172 1.1181 1.1191 1.1200 1.1208 1.1215
146....... 1.1119 1.1131 1.1141 1.1150 1.1160 1.1169 1.1177 1.1184
149....... 1.1088 1.1100 1.1110 1.1120 1.1129 1.1138 1.1146 1.1154
152....... 1.1057 1.1069 1.1079 1.1089 1.1098 1.1107 1.1115 1.1123
155....... 1.1026 1.1038 1.1048 1.1058 1.1067 1.1076 1.1085 1.1092
158....... 1.0995 1.1007 1.1018 1.1027 1.1036 1.1045 1.1054 1.1061
161....... 1.0964 1.0976 1.0987 1.0996 1.1005 1.1014 1.1023 1.1030
164....... 1.0933 1.0945 1.0956 1.0965 1.0974 1.0984 1.0992 1.0999
167....... 1.0902 1.0914 1.0925 1.0934 1.0943 1.0953 1.0961 1.0968
170....... 1.0871 1.0883 1.0894 1.0903 1.0912 1.0922 1.0930 1.0937
172....... 1.0850 1.0863 1.0873 1.0882 1.0892 1.0901 1.0909 1.0916
174....... 1.0830 1.0842 1.0853 1.0862 1.0871 1.0880 1.0889 1.0896
176....... 1.0809 1.0822 1.0832 1.0841 1.0850 1.0860 1.0868 1.0875
178....... 1.0789 1.0801 1.0811 1.0820 1.0830 1.0839 1.0847 1.0854
180....... 1.0768 1.0780 1.0791 1.0800 1.0809 1.0818 1.0827 1.0834
182....... 1.0747 1.0760 1.0770 1.0779 1.0788 1.0798 1.0806 1.0813
184....... 1.0727 1.0739 1.0749 1.0759 1.0768 1.0777 1.0785 1.0793
186....... 1.0706 1.0718 1.0729 1.0738 1.0747 1.0756 1.0765 1.0772
188....... 1.0685 1.0698 1.0708 1.0717 1.0727 1.0736 1.0744 1.0751
190....... 1.0665 1.0677 1.0687 1.0697 1.0706 1.0715 1.0723 1.0731
192....... 1.0644 1.0656 1.0667 1.0676 1.0685 1.0694 1.0703 1.0710
194....... 1.0623 1.0636 1.0646 1.0655 1.0664 1.0674 1.0682 1.0689
196....... 1.0603 1.0615 1.0625 1.0635 1.0644 1.0653 1.0661 1.0669
198....... 1.0582 1.0594 1.0605 1.0614 1.0623 1.0632 1.0641 1.0648
200....... 1.0561 1.0574 1.0584 1.0593 1.0602 1.0612 1.0620 1.0627
202....... 1.0541 1.0553 1.0563 1.0572 1.0582 1.0591 1.0599 1.0606
204....... 1.0520 1.0532 1.0542 1.0552 1.0561 1.0570 1.0579 1.0586
206....... 1.0499 1.0511 1.0522 1.0531 1.0540 1.0550 1.0558 1.0565
208....... 1.0478 1.0491 1.0501 1.0510 1.0520 1.0529 1.0537 1.0544
210....... 1.0458 1.0470 1.0480 1.0490 1.0499 1.0508 1.0516 1.0524
212....... 1.0437 1.0449 1.0460 1.0469 1.0478 1.0487 1.0496 1.0503