_Freezing._--Because of the rather large body of water contained in any type of generator, there is always danger of its freezing and rendering the device inoperative unless placed in a temperature above the freezing point of the water. It is, of course, dangerous and against the insurance rules to place a generator in the same room with a fire of any kind, but the room may be heated by steam or hot water coils from a furnace in another building or in another part of the same building.

When the generator is housed in a separate structure the walls should be made of materials or construction that prevents the pa.s.sage of heat or cold through them to any great extent. This may be accomplished by the use of hollow tile or concrete blocks or by any other form of double wall providing air s.p.a.ces between the outer and inner facings. The s.p.a.ce between the parts of the wall may be filled with materials that further r.e.t.a.r.d the loss of heat if this is necessary under the conditions prevailing.

_Residue From Generators._--The sludge remaining in the carbide to water generator may be drawn off into the sewer if the piping is run at a slant great enough to give a fall that carries the whole quant.i.ty, both water and ash, away without allowing settling and consequent clogging.

Generators are provided with agitators which are operated to stir the ash up with the water so that the whole ma.s.s is carried off when the drain c.o.c.k is opened.

If sewer connections cannot be made in such a way that the ash is entirely carried away, it is best to run the liquid ma.s.s into a settling basin outside of the building. This should be in the form of a shallow pit which will allow the water to pa.s.s off by soaking into the ground and by evaporation, leaving the comparatively dry ash in the pit. This ash which remains is essentially slaked lime and can often be disposed of to more or less advantage to be used in mortar, whitewash, marking paths and any other use for which slaked lime is suited. The disposition of the ash depends entirely on local conditions. An average a.n.a.lysis of this ash is as follows:

Sand....................... 1.10 per cent.

Carbon..................... 2.72 "

Oxide of iron and alumina.. 2.77 "

Lime....................... 64.06 "

Water and carbonic acid.... 29.35 "

------ 100.00

GENERATOR CONSTRUCTION

The water for generating purposes is carried in the large tank-like compartment directly below the carbide chamber. See Figure 11. This water compartment is filled through a pipe of such a height that the water level cannot be brought above the proper point or else the water compartment is provided with a drain connection which accomplishes this same result by allowing an excess to flow away.

The quant.i.ty of water depends on the capacity of the generator inasmuch as there must be one gallon for each pound of carbide required. The generator should be of sufficient capacity to furnish gas under working conditions from one charge of carbide to all torches installed for at least five hours continuous use.

After calculating the withdrawal of the whole number of torches according to the work they are to do for this period of five hours the proper generator capacity may be found on the basis of one cubic foot of gas per hour for each pound of carbide. Thus if the torches were to use sixty cubic feet of gas per hour, five hours would call for three hundred cubic feet and a three hundred pound generator should be installed. Generators are rated according to their carbide capacity in pounds.

_Charging._--The carbide capacity of the generator should be great enough to furnish a continuous supply of gas for the maximum operating time, basing the quant.i.ty of gas generated on four and one-half cubic feet from each pound of lump carbide and on four cubic feet from each pound of quarter, intermediate sizes being in proportion.

Generators are built in such a way that it is impossible for the acetylene to escape from the gas holding compartment during the recharging process.

This is accomplished (1) by connecting the water inlet pipe opening with a shut off valve in such a way that the inlet cannot be uncovered or opened without first closing the shut off valve with the same movement of the operator; (2) by incorporating an automatic or hydraulic one-way valve so that this valve closes and acts as a check when the gas attempts to flow from the holder back to the generating chamber, or by any other means that will positively accomplish this result.

In generators having no separate gas holding chamber but carrying the supply in the same compartment in which it is generated, the gas contained under pressure is allowed to escape through vent pipes into the outside air before recharging with carbide. As in the former case, the parts are so interlocked that it is impossible to introduce carbide or water without first allowing the escape of the gas in the generator.

It is required by the insurance rules that the entire change of carbide while in the generator be held in such a way that it may be entirely removed without difficulty in case the necessity should arise.

Generators should be cleaned and recharged at regular stated intervals.

This work should be done during daylight hours only and likewise all repairs should be made at such a time that artificial light is not needed.

Where it is absolutely necessary to use artificial light it should be provided only by incandescent electric lamps enclosed in gas tight globes.

In charging generating chambers the old ash and all residue must first be cleaned out and the operator should be sure that no drain or other pipe has become clogged. The generator should then be filled with the required amount of water. In charging carbide feed machines be careful not to place less than a gallon of water in the water compartment for each pound of carbide to be used and the water must be brought to, but not above, the proper level as indicated by the mark or the maker"s instructions. The generating chamber must be filled with the proper amount of water before any attempt is made to place the carbide in its holder. This rule must always be followed. It is also necessary that all automatic water seals and valves, as well as any other water tanks, be filled with clean water at this time.

Never recharge with carbide without first cleaning the generating chamber and completely refilling with clean water. Never test the generator or piping for leaks with any flame, and never apply flame to any open pipe or at any point other than the torch, and only to the torch after it has a welding or cutting nozzle attached. Never use a lighted match, lamp, candle, lantern, cigar or any open flame near a generator. Failure to observe these precautions is liable to endanger life and property.

_Operation and Care of Generators._--The following instructions apply especially to the Davis Bournonville pressure generator, ill.u.s.trated in Figure 11. The motor feed mechanism is ill.u.s.trated in Figure 12.

Before filling the machine, the cover should be removed and the hopper taken out and examined to see that the feeding disc revolves freely; that no chains have been displaced or broken, and that the carbide displacer itself hangs barely free of the feeding disc when it is revolved. After replacing the cover, replace the bolts and tighten them equally, a little at a time all around the circ.u.mference of the cover--not s.c.r.e.w.i.n.g tight in one place only. Do not screw the cover down any more than is necessary to make a tight fit.

To charge the generator, proceed as follows: Open the vent valve by turning the handle which extends over the filling tube until it stands at a right angle with the generator. Open the valve in the water filling pipe, and through this fill with water until it runs out of the overflow pipe of the drainage chamber, then close the valve in the water filling pipe and vent valve. Remove the carbide filling plugs and fill the hopper with 1-1/4"x3/8" carbide ("nut" size). Then replace the plugs and the safety-locking lever chains. Now rewind the motor weight. Run the pressure up to about five pounds by raising the controlling diaphragm valve lever by hand (Figure 12, lever marked _E_). Then raise the blow-off lever, allowing the gas to blow off until the gauge shows about two pounds; this to clear the generator of air mixture. Then run the pressure up to about eight pounds by raising the controlling valve lever _E_, or until this controlling lever rests against the upper wing of the fan governor, and prevents operation of the feed motor. After this is done, the motor will operate automatically as the gas is consumed.

[Ill.u.s.tration: Figure 11.--Pressure Generator (Davis Bournonville).

_A_, Feed motor weight; _B_, Carbide feed motor; _C_, Motor Control diaphragm; _D_, Carbide hopper; _E_, Carbide feed disc; _F_, Overflow pipe; _G_, Overflow pipe seal; _H_, Overflow pipe valve; _J_, Filling funnel; _K_, Hydraulic valve; _L_, Expansion chamber; _M_, Escape pipe; _N_, Feed pipe; _O_, Agitator for residuum; _P_, Residuum valve; _Q_, Water level]

[Ill.u.s.tration: Figure 12.--Feed Mechanism of Pressure Generator]

Should the pressure rise much above the blow-off point, the safety controlling diaphragm valve will operate and throw the safety clutch in interference and thus stop the motor. This interference clutch will then have to be returned to its former position before the motor will operate, but cannot be replaced before the pressure has been reduced below the blow-off point.

The parts of the feed mechanism ill.u.s.trated in Figure 12 are as follows: _A_, motor drum for weight cable. _B_, carbide filling plugs.

_C_, chains for connecting safety locking lever of motor to pins on the top of the carbide plugs. _D_, interference clutch of motor.

_E_, lever on feed controlling diaphragm valve. _F_, lever of interference controlling diaphragm valve that operates interference clutch.

_G_, feed controlling diaphragm valve. _H_, diaphragm valve controlling operation of interference clutch. _I_, interference pin to engage emergency clutch. _J_, main shaft driving carbide feeding disc. _Y_, safety locking lever.

_Recharging Generator._--Turn the agitator handle rapidly for several revolutions, and then open the residuum valve, having five or six pounds gas pressure on the machine. If the carbide charge has been exhausted and the motor has stopped, there is generally enough carbide remaining in the feeding disc that can be shaken off, and fed by running the motor to obtain some pressure in the generator. The desirability of discharging the residuum with some gas pressure is because the pressure facilitates the discharge and at the same time keeps the generator full of gas, preventing air mixture to a great extent. As soon as the pressure is relieved by the withdrawal of the residuum, the vent valve should be opened, as if the pressure is maintained until all of the residuum is discharged gas would escape through the discharge valve.

Having opened the vent pipe valve and relieved the pressure, open the valve in the water filling tube. Close the residuum valve, then run in several gallons of water and revolve the agitator, after which draw out the remaining residuum; then again close the residuum valve and pour in water until it discharges from the overflow pipe of the drainage chamber. It is desirable in filling the generator to pour the water in rapidly enough to keep the filling pipe full of water, so that air will not pa.s.s in at the same time.

After the generator is cleaned and filled with water, fill with carbide and proceed in the same manner as when first charging.

_Carbide Feed Mechanism._--Any form of carbide to water machine should be so designed that the carbide never falls directly from its holder into the water, but so that it must take a more or less circuitous path. This should be true, no matter what position the mechanism is in. One of the commonest types of forced feed machine carries the carbide in a hopper with slanting sides, this hopper having a large opening in the bottom through which the carbide pa.s.ses to a revolving circular plate. As the pieces of carbide work out toward the edge of the plate under the influence of the ma.s.s behind them, they are thrown off into the water by small stationary fins or plows which are in such a position that they catch the pieces nearest the edges and force them off as the plate revolves. This arrangement, while allowing a free pa.s.sage for the carbide, prevents an excess from falling should the machine stop in any position.

When, as is usually the case, the feed mechanism is actuated by the rise or fall of pressure in the generator or of the level of some part of the gas holder, it must be built in such a way that the feeding remains inoperative as long as the filling opening on the carbide holder remains open.

The feed of carbide should always be shut off and controlled so that under no condition can more gas be generated than could be cared for by the relief valve provided. It is necessary also to have the feed mechanism at least ten inches above the surface of the water so that the parts will never become clogged with damp lime dust.

_Motor Feed._--The feed mechanism itself is usually operated by power secured from a slowly falling weight which, through a cable, revolves a drum. To this drum is attached suitable gearing for moving the feed parts with sufficient power and in the way desired. This part, called the motor, is controlled by two levers, one releasing a brake and allowing the motor to operate the feed, the other locking the gearing so that no more carbide will be dropped into the water. These levers are moved either by the quant.i.ty of gas in the holder or by the pressure of the gas, depending on the type of machine.

With a separate gas holder, such as used with low pressure systems, the levers are operated by the rise and fall of the bell of the holder or gasometer, alternately starting and stopping the motor as the bell falls and rises again. Medium pressure generators are provided with a diaphragm to control the feed motor.

This diaphragm is carried so that the pressure within the generator acts on one side while a spring, whose tension is under the control of the operator, acts on the other side. The diaphragm is connected to the brake and locking device on the motor in such a way that increasing the tension on the spring presses the diaphragm and moves a rod that releases the brake and starts the feed. The gas pressure, increasing with the continuation of carbide feed, acts on the other side and finally overcomes the pressure of the spring tension, moving the control rod the other way and stopping the motor and carbide feed. This spring tension is adjusted and checked with the help of a pressure gauge attached to the generating chamber.

_Gravity Feed._--This type of feed differs from the foregoing in that the carbide is simply released and is allowed to fall into the water without being forced to do so. Any form of valve that is sufficiently powerful in action to close with the carbide pa.s.sing through is used and is operated by the power secured from the rise and fall of the gas holder bell. When this valve is first opened the carbide runs into the water until sufficient pressure and volume of gas is generated to raise the bell. This movement operates the arm attached to the carbide shut off valve and slowly closes it. A fall of the bell occasioned by gas being withdrawn again opens the valve and more gas is generated.

_Mechanical Feed._--The previously described methods of feeding carbide to the water have all been automatic in action and do not depend on the operator for their proper action.

Some types of large generating plants have a power-driven feed, the power usually being from some kind of motor other than one operated by a weight, such as a water motor, for instance. This motor is started and stopped by the operator when, in his judgment, more gas is wanted or enough has been generated. This type of machine, often called a "non-automatic generator,"

is suitable for large installations and is attached to a gas holder of sufficient size to hold a day"s supply of acetylene. The generator can then be operated until a quant.i.ty of gas has been made that will fill the large holder, or gasometer, and then allowed to remain idle for some time.

_Gas Holders._--The commonest type of gas container is that known as a gasometer. This consists of a circular tank partly filled with water, into which is lowered another circular tank, inverted, which is made enough smaller in diameter than the first one so that three-quarters of an inch is left between them. This upper and inverted portion, called the bell, receives the gas from the generator and rises or falls in the bath of water provided in the lower tank as a greater or less amount of gas is contained in it.

These holders are made large enough so that they will provide a means of caring for any after generation and so that they maintain a steady and even flow. The generator, however, must be of a capacity great enough so that the gas holder will not be drawn on for part of the supply with all torches in operation. That is, the holder must not be depended on for a reserve supply.

The bell of the holder is made so that when full of gas its lower edge is still under a depth of at least nine inches of water in the lower tank. Any further rise beyond this point should always release the gas, or at least part of it, to the escape pipe so that the gas will under no circ.u.mstances be forced into the room from, between the bell and tank. The bell is guided in its rise and fall by vertical rods so that it will not wedge at any point in its travel.

A condensing chamber to receive the water which condenses from the acetylene gas in the holder is usually placed under this part and is provided with a drain so that this water of condensation may be easily removed.

_Filtering._--A small chamber containing some closely packed but porous material such as felt is placed in the pipe leading to the torch lines. As the acetylene gas pa.s.ses through this filter the particles of lime dust and other impurities are extracted from it so that danger of clogging the torch openings is avoided as much as possible.

The gas is also filtered to a large extent by its pa.s.sage through the water in the generating chamber, this filtering or "scrubbing" often being facilitated by the form of piping through which the gas must pa.s.s from the generating chamber into the holder. If the gas pa.s.ses out of a number of small openings when going into the holder the small bubbles give a better washing than large ones would.

_Piping._--Connections from generators to service pipes should preferably be made with right and left couplings or long thread nipples with lock nuts. If unions are used, they should be of a type that does not require gaskets. The piping should be carried and supported so that any moisture condensing in the lines will drain back toward the generator and where low points occur they should be drained through tees leading into drip cups which are permanently closed with screw caps or plugs. No pet c.o.c.ks should be used for this purpose.

For the feed pipes to the torch lines the following pipe sizes are recommended.