Professional Documents
Culture Documents
Vb’I—IEREAS, for the practice oI’ niechanical enginecri tie. I he Hoard adopted and
promulgated the PSM [F Code;
WhEREAS, there hasteen an urgent and i niportant iced for the updatemenl and
revision of the said Code to cope up with ttic rapid, continuous advancement in
mechanical engineering technology that has brought about economic rowtli and
development:
WhEREAS, in lesponse to such need, the PS ME. I TIC., and the other alit late
sectors of the profession have come up with the Revised Philippine Mcclianical Code,
2007 Edition;
WHEREAS, this new Code presents topics with a balanced coverate of relevant
fundamental and realworld practices that would ensure our mechanical engineers to
enhance and maintain high professional, technical, and ethical standards br the practice
of mechanical engineering profession;
WHEREAS, as part of the Rules and Regulations of the Board, violation of any
provision of this Code is a ground for d iscipi i I1aT’y act on against a pro Icssioiial
mechanical engineer, registered mechanical engineer, and certified plant ineclianic
This Code shall take effect a fter fifteen (1 5) (lays tbl lowing its lull and complete
in the
publication in the Official Gazette or iii a newspaper I general eiren latini
Philippines.
ALFRY.
(‘,{inirniaii 7
PALISBO (VACAN’I’)
(_,,/‘ rnber M ember
OS G. ALMELOR
Secretary, Professional
Regulatory Boards
A P PRO \/ ED:
LEONOR TRLPON-ROSFRO
Chairperson
4 ROSAS
RUTH RANA PADJ.LLA
Coinmi ssi oner
PRB-MEF]D-SRB
AYP/CGA/ofie
a: revised me code 2007
PHILIPPINE SOCIETY OF MECHANICAL ENGINEERS
INTEGRATED ASSOCIATION OF MECHANICAL ENGINEERS
MEMBERS
PACIFICO 0. ORTALIZA
CARMELITO A. ALUNAN
CIPRIANO A. MARCELO
1{publlc of II1i Iiipin
rnfcrnwf Ruftzfion QIummon
MESSAGE
This publication is an effective research and resources material, not only for
mechanical engineers but also for those who seek relevant information to guide
the general public on efficiency and quality performance. It sets forth the stan
dards of professional conduct thereby ensuring that if faithfully conforms to the
implementation of Republic Act No. 8495, otherwise known as the “Philippine
Mechanical Engineering Act of 1998”, and provides for the remedial measures
or sanctions for any violation.
This contribution to the society epitomizes your earnest desire to harmonize and
unite all mechanical engineers and provide a guiding path in achieving profes
sional excellence, integrity, humility and service. This worthy project of PSME
will surely mark another milestone of success, as you continue to broaden the
horizon and expand the boundaries of Filipino mechanical engineers.
LEONOR TRIPON-ROSERO
Secretary August 1, 2008
MESSAGE
It is the dream of many, if not all to become experts in their chosen fields of
endeavor, and this Code is symbolical of the Society’s commitment to make
sure that the professionals remain true to their sworn duty to serve and
contribute to the progress of our nation, and improve quality of life.
RUTH RANA-PADILLA
August 1, 2008 Commissioner
MESSAGE
4’L
NILO L. ROSAS
Commissioner
August 1, 2008
MESSAGE
This vital reference book puts together expertise of private practitioners and
various references for mechanical engineers to continuously cope up with
the advancement of technology, formulating and adopting techniques and
systems relevant in the Philippine condition and to constantly uphold the
ideals of integrity, spiritual values, and commitment to serve the nation.
This effort of the men and women of the PSME functions greatly in the
administrative supervision of the Board over its professionals. Your
invaluable role in providing this reference reflects your commitment to
professionalism. I believe that only through this comprehensive information
campaign that we will be able to observe, implement and uphold
professional excellence.
PROFESSIONAL REGULATION
C MM Is SI 0 NJ
LEONOR TRIPON-ROSERO
Chairperson
BOARD OF MECHANICAL
N G I M E F? I N G
ENGR. ALFREDO Y. P0
Chairman
1
HON. JOVENCIO C. PALISBO VACANT
Member
PREFACE 2008 EDITION
This code undertakes a significant change for an advanced study of certain provisions of Mechani-
cal Engineering in the realization of our Global climate change and trends, to address relevant
needs of the future. All PSME Chapters have given their contributions to uplift the standards of our
Code to a more meaningful practice of the Mechanical Engineering Profession.
Our present trend is to venture into a cleaner and greener environmental field. For and in consi
derations of these fields, we adopted the latest revision of the American, European and Japanese
Mechanical Codes which were deemed applicable and relevant to Philippine Conditions, the as
pects of which were clearly defined and illustrated. Moreover, prevailing Philippine conditions has
greatly affected and influenced, with the end in view, such that private practitioners’ inputs were
solicited, reviewed and included in many chapters.
All changes, additions and amendments came about after careful and thorough deliberations and
evaluations by the code committee resulting in simple clarifications and explanations
In case of conflicts in the Interpretation of the provisions of this code, the Board of Mechanical
Engineering, Professional Regulation Commission, shall be the arbiter whose decision shall be
final and unappealable.
The Code and Standards Committee welcomes comments, inputs and suggestions for the improve
ment of this code especially on omissions, errors, conflicts, etc... arising from the final printing of
this code. All suggestions / comments shall then be reviewed and deliberated upon for possible
inclusion in the next edition, as this is a continuing process for evaluation, advancement and prog
ress.
4.
czz
L
/
EDUARDO P. MENCIAS
PSME National President 1979, 1980
Chairman, 2008 Code & Standards Committee
PHILIPPINE SOCIETY OF MECHANICAL ENGINEERS
INTEGRATED ASSOCIATION OF MECHANICAL ENGINEERS
Scope Definitions • General Requirements• Identification Colors for Pipes. Fluid Flow
Velocities • Power Piping System Design • Industrial Gas and Air Piping System
• Refrigerator Piping Systems
241
12 METROLOGY
Purpose and Scope. Definitions • Measurement Concepts • Classification of the
Common Measuring Instruments Used in lndustry• Graduated Manual Measuring tools
• Non-Graduated Manual Measuring Tools• Special Purpose Measuring Tools
• Non-Destructive Inspection Pressure and Vacuum Measurements Thermometry
and Pyrometry. Flow Metering Measurement of Weight The Three Common
Methods of Rotational Speed Measurements • Environmental and Pollution
Measurements
263
13 MACHINE SHOP MACHINERY AND EQUIPMENT
Purpose and Scope • Standard Machine • Special Tools and Machinery in Machine Shop
of a Manufacturing Plant • Sizes of Motors for Machine Shop Equipment and Forging
Machinery• Machine Screws Gearing Guarding of Point of Operating in Turning,
Drilling, Shaping, Milling And Grinding Operations
282
14 MANUFACTURING PROCESSES
Definitions Classification of Manufacturing Processes • Processes • Shielded Metal Arc
Welding . Safety Precautions • Pollution Control • Anti- Pollution for Manufacturing Processes
298
15 FUELS AND LUBRICANTS
Fuels . Solid Fuels • Coke • Wood and Hogged Fuel • Miscellaneous Solid Fuels
• Liquid Fuels Storage and Handling of Fuel Oil • Gasoline and Kerosene • Diesel Fuel
‘
Chapter 1
GENERAL
This chapter provides the general requirements for (b) Complete individual piping system,
works involving machinery design, installations and indicating terminal to terminal valves,
operations. fittings, size and color code.
As used in this code, and as defined in Article I 2.4 Separate plan for the different store rooms, fuel
Section 3 Paragraph (b) Republic Act No. 8495, tanks, fire extinguishing equipment, fire fighting
otherwise known as The New Mechanical Engineering tools, fire doors, fire escape ladders, etc., which
Law, mechanical equipment/machinery or process were not incorporated in Section 2.1.
shall include steam engines, internal combustion
engines, boilers, turbines, crushers, mills, mixers, 2.5 For air conditioning and refrigeration installation
compressors, cranes, conveyors, hoists elevators, or ventilation, plans for supply and return
pipelines, line shafting, etc.; and the term “mechanical ductwork should indicate the location of outlet
works, plant,” shall include steam plants, internal dampers, controls, filters, fire proofing, sound
combustion engine plant, hydraulic power plants, insulators.
pumping plants, refrigerating plants, air-conditioning
plants, mill shops, factories, shipyards, etc. containing 2.6 Detailed plans of foundations and supports.
any mechanical equipment, machinery or process.
2.7 Detailed construction and working plans of
Section 2.0 Requirements for Permit boilers and pressure vessels, if any.
Application 2.8 Location plan preferably drawn to scale.
All proposed installations, additions or alterations
involving machinery, mechanical equipment or 2.9 Complete list of machineries showing:
process shall be covered by the following plans and
specifications prepared by or under the supervision of (a) Machinery name:.
a Professional Mechanical Engineer signed and
sealed by same. Such plans in triplicate shalt (b) Catalogue number, size, model, serial
accompany applications for installation and operation number
permit.
(c) Rated capacity (Ex. Boiler Steam capacity in
Kg/Hr, kW, kJ)
2.1 General layout plan for each floor drawn to scale
not less than 1:200, in heavy lines the (d) Drive and Revolutions per minute
equipment with super-imposed building outline
in light or suppressed lines. All names of (1) Direct
machinery and brake horsepower or kilowatt
rating should be noted on plan. (2) V-belt or flat belt
2.2 Plan elevation at least one longitudinal and one (3) Gear reducer
traverse to show inner floor relations indicating
how machines are supported whether through (4) Hydraulic
building structure, separate staging or by
foundations from the ground. (5) Magnetic
I
____
CHAPTER 1 - GENERAL
2
CHAPTER 1 - GENERAL
PENCIL LINES INK LINES
THICK THICK
VISIBLE LINE
MEDIUM MEDIUM
MIDDEN LINE 2
THIN TI4tN
3 SECTION LINE
THIN THIN
4 CENTERLINE 4 —
Leader ,— Leader
5 Extension Line Extension Line
Dimension Line
ThIN
I DIMENSION
Oimensin Line
THIN VI_ v/
6 LINE
EXTENSION r161I
LINE
Fig. 1-4 Application of surface symbol to drawings
7. THIN
I
ANDREADERS
1714 THIN
4__ —
— THICK — — __4i CUTTING -PLANE { 8
L —
— THICK —
—
LINES OR
VIEWING-PLANE
LINES
9 4__ —
— THICK —
—
THICK THICK
10 10
}
—.———-——--—-——————— ...—.—._——-—-.——.——————
.
EREAK LINES
4
T__
y THIN
THIN THIN
12 ——
PHANTOM LINE 12 — —
.002 - 2 .002-2
Maximum waxiness width rating Where required, maximum
is placed above the horizontal 63 7i’ roughness width rating shed be
extension and to the right of the 3,/’.L. .020 parted at the right of the lay
waviness height rating. Any len symboL Any lesser rating shall
serrating shat be acceptable. be acceptable.
3
CHAPTER 1 - GENERAL
Standard sheet sizes for mechanical plans and Section 4.0 Inspection
drawings shall be based on a width to length
ration of 1: square root of 2. All borders shall be 4.1 Inspection shall be done during installation to
at least 10 mm from the sheet edge; and all title satisfy inspection office of respective
blocks shall be located at the lower right hand government agency concer ned that all materials
corner inside borders for larger sheets, and and method s of erectio n are inspected in
throughout the lower sheet border for smaller confor mance with this code.
sheets. Standard sheet sizes shall be as follows:
4.2 Annual inspection shall be made to see that:
1. A4:210x297mm
2. A3:297x420mm (a) Equipment as originally installed are still
3. A2:420x594mm safe to operate for at least another year.
4. A1:594x840mm
5. 375x530mm (b) No change, addition or alteration deviating
6. 530x750mm from the original plan was made without
7. 750x1065mm prior permit from the proper government
agency concerned.
A. Use of Computers
4
CHAPTER 1 - GENERAL
150mm
checked
by scale sheet no.
p. m. e. owner
20 20
5
CHAPTER 2- COMMERCIAL AND INDUSTRIAL BUILDING
Chapter 2
6
CHAPTER 2- COMMERCIAL AND INDUSTRIAL BUILDING
projections and obstructions which might a. Manhole floor openings shall be provided
create stumbling hazards. with manhole covers of adequate strength
which need not be hinged.
3.4 Slipping Hazards
b. Other floor openings into which persons can
a. Floors, stair treads and landings shall not be accidentally fall through shall be guarded
slippery under any condition or made of any either by permanent railings and toe boards
material which will become slippery through on all exposed sides or by hinged floor
wear. In the case of concrete stairs, it opening covers of adequate strength.
should have a rough finish and for steel
stairs, checkered plate or standard metals c. When covers for either type are not in place,
and non-slip strip shall be used. the opening shall be constantly attended to
by someone or protected by portable
b. Stairways, ramps, elevators, platforms and enclosing railings.
similar places where slipping may be
especially hazardous, shall be provided with d. Floor openings into which person can
non-slip walkway surfaces. accidentally walk on account of fixed
machinery, equipment or walls shall be
3.5 Floor and Wall Opening: guarded by covers securely held in place
and leaving no openings more than 25 mm
a. Ladder way, floor openings shall be guarded in width or by toe boards on all exposed
on all exposed sides, except at the entrance sides.
to the opening, by permanent railings and
toe boards, the passage through the railings e. All wall openings less than 1 000 mm from
shall be provided with a barrier or gate so the floor having a height of at least 750 mm
arranged that a person cannot walk directly and width of 450 mm from which there is a
into the opening. drop of more than 2 000 mm shall be solidly
enclosed or guarded by fixed or rolling
b. Stairway floor openings shall be guarded on barrier rails, picket fences, half doors, or
all exposed sides, except at the entrance to equivalent barriers, capable of withstanding
he stairway, by permanent railings and toe a load of at least 100 kg applied in any
boards. direction except vertically upward at any
point on the top or corresponding member.
c. For seldom used stairways where traffic
across the opening prevents the use of f. All other wall openings, irrespective of their
permanent railings, the guard shall consist width shall, if their lower edge either 80 mm
of a flush-hinged cover of adequate strength or less above floor level on the near side or
equipped with railings attached thereto so 2 000 mm or more above ground, or floor
as to leave only one side exposed when the level on the far side, be guarded by:
cover is open.
1. A toe board across the bottom of
d. Hatchway chute, pit and trap door openings the opening or
(it cold be an elevator pit or a maintenance
pit) shall be guarded by: 2. An enclosing screen, either solid or
of grilles or slat work with openings
1. Removable railings with toe boards not more than 25 mm in width.
on not more than two sides and
permanent railings with toe boards 3.7 Railings
on all other exposed sides, or
a. All railings shall be constructed in a
2. Flush-hinged cover as specified for permanent and substantial manner of wood,
stairway floor openings. pipe, structure metal or other material of
sufficient strength.
3.6 Manholes and Other Openings
b. Standard railings shall be at least 1 000 mm
from the upper surface of the top rail to floor
level.
7
CHAPTER 2- COMMERCIAL AND INDUSTRIAL BUILDING
c. Standard railings shall have posts not more b. Width of stairs except service stairs, i.e.
than 2 000 mm apart and an intermediate giving access to oiling platforms, shall in no
rail halfway between top rail and the floor. case be less than 900 mm and should be at
least 1 120 mm away from all obstruction
d. The dimensions of railings and posts and except handrails.
the anchoring and framing of members shall
be such that the completed structure shall c. Except for service stairs, the pitch of
be capable of withstanding a load of at least stairways should be between 30° and 38°
100 kg applied in any direction at any point from the horizontal and the slope should not
of the top rail. be less than 20° or more than 45°.
e. Railing of the following types of construction d. Where the slope would be less than 20°, a
shall be deemed satisfactory: ramp should be installed, and where the
slope is more than 45°, a fixed ladder should
1. For Wood Railings: Top rails and be provided.
posts of at least 50 mm x 100 mm
stock and intermediate rails of at e. No stairway shall have a height of more than
least 50 mm x 50 mm x 20 mm x 2 750 mm between landings, and
100 mm stock. All such railings intermediate landings shall have dimensions
shall be smooth and free from large of not less than 1 120 mm measured in the
or loose knots, protruding nails or direction of the run.
bolts, splinters, fine slivers or
cracks. f. Headroom shall be provided at all points in
the stairwell. The vertical clearance shall not
2. For Pipe Railings: Top rails and be less than 2 200 mm from the top of the
posts of metal pipe of at least 30 tread in line with the face of the riser.
mm diameter. And intermediate rails
of metal pipe of at least 25 mm g. Except for service stairs, the treads,
diameter. exclusive of noosing or projections, shall not
be less than 230 mm in width and the risers
3. For Structural Metal Railings: Top shall not be more than 200 mm or less than
rails and posts of angle iron at least 130 mm in height.
38 mm x 38 mm x 5 mm and
intermediate rails of angle iron of at h. There shall be no variation in the width of
least 32 mm x 32 mm x 3 mm. the treads and the heights of the risers in
any flight; the top and bottom treads of any
f. All railings shall be of sound material free flight should be clean’ distinguishable.
from defects and all sharp corners shall be
rounded and smoothed. All stairways having four or more risers shall
be equipped with stair railings on any open
g. Toe boards shall be at least 150 mm in side.
height.
j. Enclosed stairways less than 1 120 mm in
h. Toe boards may be made of wood, iron, width shall be equipped with the stair
steel or other substantial material. railings on any open side.
Toe boards shall be securely fastened in k. Enclosed stairways less than 1 120 mm in
place with not more than 6-mm clearance width shall be equipped with at least one
above floor level. handrail, preferably on the right side
descending.
3.8 Stairs
Stairways 1120 mm or more in width shall
a. All stairs, platforms, and landings shall be of be equipped with one stair railing on each
sufficient strength to sustain safely a live open side and one handrail on each
load of not less than 500 kg with a factor of enclosed side.
safety of four (4)
8
CHAPTER 2- COMMERCIAL AND INDUSTRIAL BUILDING
m. In addition to the railings provided for in slats, or grill work to prevent persons from
Section 3.8, stairways 2 250 mm or more in falling through.
width shall be equipped with an intermediate
handrail located approximately midway of x. Ramps used by persons for ascent or
the width. descent from one level to another shall be
limited to a slope of not more than 1 in 10
n. Stair railings shall be constructed in a and shall conform to all relevant
permanent and substantial manner of wood, requirements for construction width,
pipe, structural metal or other material of enclosures and railings applying to
sufficient strength. stairways.
o. The height of stair railings, from the upper y. Where railings for ramps may be subjected
surface of the top rail to the surface of the to heavy stresses, from trucking or handling
tread in line with the face of the riser at the materials, additional strength shall be
forward edge of the tread, shall not be more provided by use of heavier stock, close
than 860 mm nor less than 760 mm. spacing of posts, bracing, etc.
p. Handrails shall be continuous throughout a 3.9 Fixed Ladders, Catwalks, Runways and
flight of stairs and at landings and without Platforms:
obstructions other than those intended to
prevent persons from sliding. a. All metal parts or fittings of ladders shall be
made of structural steel.
q. If made of wood, handrails shall be at least
50 mm x 50 mm in cross section and if of b. Fixed ladders shall be so installed that:
metal pipe, at least 40 mm in diameter.
1. The distance from the front of the
r. Handrails mounted directly on walls or rungs to the nearest fixed object on
partitions shall be fixed by means of the climbing side of the ladder is at
brackets attached to the lower side of the least 760 mm.
rails, so as not to interface with the
smoothness of the top and side surfaces of 2. The distance from the back of the
the rails. rungs to the nearest fixed object is
at least 160 mm.
s. Brackets shall be spaced not more than
2 000 mm apart and shall be of sufficient 3. Except in the case of ladders
strength to provide a clearance of at least 40 equipped with cages, baskets or
.m betweent1e rails and walls or any equivalent devices, there should be
.)structlon on the walls a clearance of at least 380 mm from
the center line of the ladder on
t The completed structure shall be capable of either side across the front of the
withstanding a load of at least 100 kg ladder.
applied in any direction at any point on the
rail. c. If fixed ladders are used to ascent height
exceeding 9 000 mm.
u. The clear width of. service stairs, such as
stairs in engine and boiler rooms or stairs 1. Landing platforms should be
leading to service platforms around provided for each 9 000 mm or a
machinery, shall be at least 560 mm. fraction thereof.
v. The pitch of service stairs shall not be more 2. The sections of the ladder should be
than 60° and the width of the treads shall staggered.
not be less than 150 mm.
d. Catwalks, working platforms or open sided
w. Window openings at stair landings, where floors 2 000 mm or more above floor or
the opening is more than 300 mm in width ground level, except platforms used for
and the sill is less than 900 mm above the loading and unloading of height, and small
landing shall be guarded securely by bars, platforms used for motors or similar
9
CHAPTER 2- COMMERCIAL AND INDUSTRIAL BUILDING
equipment which cannot afford standing bridges or under pass should be provided,
space for persons, shall be guarded on all and the track or roadway should be fenced
open sides by standard railing and toe so as to prevent direct crossing at such
boards. points.
e. Catwalks used for filling of thanks, cars or j. Walking along railway tracks by
for oiling may have the railing on one side unauthorized persons should be prohibited.
omitted, if necessary, subject to the hazard
of falling being reduced by the use of k. Railings should be installed along walkways
runways not less than 560 mm in width. on bridges, on steep slopes, at slippery
places and at places where pedestrians are
f. All runways or platforms constructed over liable to injury by passing vehicles.
conveyors or machinery shall be guarded on
all open sides by standard railings and toe Roadways for automobiles, tractors or other
boards. vehicles should be soundly constructed with
surfaces made of good working materials.
3.10 Yards, Gates, Roadways, Walkway
m. Roadways should be of adequate width, and
a. Plant yards shall be properly drained and where used by two way traffic, shall be at
graded in order to facilitate safe access to least twice the width of the widest vehicle
buildings and safe handling of material and normally used, plus 1,2500 mm. Sufficient
equipment. clearance from overhead structure should
be provided.
b. Drain pools and catch basins shall be
provided where necessary, and be properly n. Where the establishment of grade or level
covered or enclosed. crossings cannot be avoided, such
crossings should be protected by watchman,
c. Ditches, pits and other hazardous openings gates or automatic signals.
shall be provided with substantial covers,
enclosed, or surrounded by substantial o. Substantial railings or walls should be
guards. provided along bridges, slopes and sharp
curves.
d. Walkways, roadways and tracks for plant
railways should be carefully laid out in such Section 4.0 Machinery & Equipment
a manner as to avoid dangerous grade
crossings. 4.1 General Requirements
e. Where the premises are surrounded by a. All heavy machinery should be supported on
fences or walls, separate entrance and exit solid foundations of sufficient mass and
gates should be provided for pedestrians, base area to prevent or minimize the
vehicular and railroad traffic. transmission of objectionable vibration to the
building and occupied space and to maintain
f. Gates for pedestrian traffic should be the supported machine at its proper
located at a safe distance from those for elevation and alignment.
vehicular and railroad traffic and should be
of sufficient width to permit passage of b. Foundation mass should be from 3 to 5
employees at rush hours. times the weight of the machinery it is
supposed to support, or may be designated
g. Safe walkways should be constructed along in conformance with Section 2.4. .2.
the shortest lines between important points.
If the unbalanced inertial forces produced by
h. Walkways should not be located under the the machine can be calculated, a mass of
eaves of buildings where they may become weight equal to 10 to 20 times the forces
slippery. should be used to dampen vibration.
Where it is necessary for pedestrians to For stability, the total combined engine,
cross railroad tracks or vehicular roadways, driven equipment, and foundation center of
10
CHAPTER 2- COMMERCIAL AND INDUSTRIAL BUILDING
11
CHAPTER 2- COMMERCIAL AND INDUSTRIAL BUILDING
12
CHAPTER 2- COMMERCIAL AND INDUSTRIAL BUILDING
13
CHAPTER 3— POWER TRANSMISSION EQUIPT., PRIME MOVERS, MACHINES AND MACHINE PARTS
Chapter 3
of danger zones except those within the points of in securing uniform motion of machinery by resisting
operation of machinery utilized in various industries. sudden changes of speed. A mechanical energy
Considerations for machine guarding and safety storage device that stores momentum in a dynamically
provisions at the point of operation are covered under balanced rotating mass and releases it through the
Chapter 4. Provisions of this chapter shall not be action of clutches, cams, gears or other intermittent
interpreted as alternatives to those described in other arrangement which engages resisting loads against
chapters of this Code. the momentum of the wheel.
operation, the prime mover and the transmission utilizing the energy from expanding combustion gases
system, where personnel or materials other than those to produce mechanical energy. Internal combustion
in process in the machine may come in contact, or be engines may be classified according the type of fuel
caught by or between moving and/or stationary parts used (i.e. gasoline, diesel, propane, etc.); according to
of the machine. This includes areas where materials or the arrangement of combustion cylinders (i.e. vertical
stock are fed into, processed and/or discharged from in-line, vee, Lenoir, Brayton, Otto, jet, 2-stroke, 4-
the machine. stroke, etc.). Suitable guarding and protection shall be
provided against heat, vibration, noise, explosion and
Electric Motors normally a prime mover utilizing
—
fire.
magnetic energy from flowing electric currents to
produce mechanical energy, usually in the form of Machine the driven unit, appliance or equipment as
rotational or shaft energy. While electric motors may
—
14
CHAPTER 3- POWER TRANSMISSION EQUIPT., PRIME MOVERS, MACHINES AND MACHINE PARTS
15
CHAPTER 3— POWER TRANSMISSION EQUIPT., PRIME MOVERS, MACHINES AND MACHINE PARTS
16
CHAPTER 3— POWER TRANSMISSION EQUIPT., PRIME MOVERS, MACHINES AND MACHINE
PARTS
railing guards having toe boards of midrail e. Conveyors passing over areas that are
height or by substantial cover or gratings. occupied or used by employees shall be so
guarded as to prevent the material handled
b. All belt conveyor head pulleys, tail pulleys, from falling on and causing injury to
single tension pulleys and dip take-up employees.
pulleys shall be so guarded that the entire
sides of the pulleys are covered and the f. Where workmen pass under the return
guard shall extend in the direction of the run strands of chain conveyors a shallow trough
of the belt at such distance that a person or other effective means of sufficient
cannot reach behind it and be caught in the strength to carry the weight of the broken
nip point between the belt and the pulley. chain shall be provided.
c. Portable inclined conveyors shall have head 3.8 Process Machine Power Control:
and tail pulleys or sprockets and other
power transmission equipment guarded a. Each process machine driven by an
accordingly. individual prime mover shall be equipped
with emergency stopping device which can
d. Where necessary to pass over exposed be safely actuated from the operator’s
chain, belt, bucket, screw, or roller working position unless the machine is
conveyors, such crossovers shall be equipped with automatic clutch which will
provided with catwalk or bridge with stop or disengage all machine operation.
standard railings and toe boards and shall
have a safe means of access either fixed b. Where an operator attends one or more
ladder, ramp, or stairway. process machines not equipped with
individual drives, each machine shall be
Table 3.1 Materials for “U” Guards equipped with stopping device which can be
13
safely actuated from the operator’s working
B Mm. position at the machine, such a stopping
A Largest C
Minimum Height of device may stop an entire group of
Material Clearance at Mesh or Guard
All Points Opening Thickness
from
machines by stopping the prime mover,
(mm) Allowed Gage No. power transmission or it may be a machine
(mm) Gage #
—
Floor
(mm) Level clutch, cut-off coupling, or tight and loose
(mm)
Woven Wire under 100 10 1.6 mm (#16)
pulley with belt shifter which can stop all the
1,800
Woven Wire 100— 380 50 2.8mm (#12) 1500 machine. Pole or hand shifting of belt is not
Expanded Metal under ico 10 1.25mm (#18) 1,800 considered adequate means for
ExpandedMetal 100—380 50 2.36mm(#13) 1,500 disconnecting the power.
Perforated Metal Under 100 10 .65 mm (#20) 1,800
Perforated Metal 100— 380 50 2.00 mm (#24) 1,500 Exception: Where due to the process,
Sheet Metal Under 100 - .80mm (#22) 1,800 machines must be operated in groups, the
Sheet Metal 100— 380 - .80 mm (#22) 1500 machine power control may stop the entire
Plywood or Under 100 - 6mm 1,800 group of machines, such group drives shall
equivalent
Plywood or
be provided with conveniently located,
100—380 6mm 1,500
equivalent
-
17
PARTS
CHAPTER 3— POWER TRANSMISSION EQUIPT., PRIME MOVERS, MACHINES AND MACHINE
designed, installed, and/or located that they and where the distance between any two
are not likely to operate from accidental adjacent belts or pulleys does not exceed
contact with objects or parts of the body. 900 mm.
3.9 Machine Power Control. All machines shall be f. Horizontal overhead belts more than 2 100
equipped with adequate means whereby the mm above a floor, platform or other working
operator of the machine or some other person level shall be guarded for their entire length
may disconnect the power promptly in case of if located over passageways or working
emergency. places.
3.10 Revolving and Reciprocating Parts g. Wherever there pulleys of such dimensions
and so located as to permit passage
a. Hazardous revolving or reciprocating parts between upper and lower runs of belt,
in any machine not guarded by the frame or standard railing guard shall be constructed;
the machine or by location shall be guarded. or all space traversed by belt shall be
completely barred against passage.
b. Keys, set screws, projections or recess in
revolving parts not guarded by the frame of h. Continuous system rope drives so located
the machine or by location shall be that the condition of the rope (particularly
removed, made flush or guarded. the splice) cannot be constantly and
conveniently observed shall be equipped
3.11 Collars and couplings shall be cylindrical and no with a “telltale” device (preferably electric
screws or bolts project beyond largest periphery. bell type) that will give warning when rope
begins to fray.
3.12 Clutches, cut-off couplings or clutch pulleys,
having projecting parts where any parts of such i. All rope drives shall be guarded as required
devices is located or 2 100 mm or less above for belt drives.
the floor or working level shall be guarded.
3.14 Counter-balanced belt tensioner and all parts
3.13 Guarding of Belt and Pulley Drives: thereof shall be of substantial construction.
Means shall be provided to prevent the
a. Any part of a belt and pulley drive involving tensioner from falling in case the belt breaks; or
the use of flat crowned or flanged pulleys, the area directly beneath the tensioner shall be
which is 2 100 mm or less above the floor or guarded by standard railing guards.
working level shall be guarded.
3.15 Belt-type variable speed drives located 2 100
b. Flat step-cone pulleys drives upon which the mm or less from the floor or working level shall
belt operates on one step only, or step cone have all moving parts guarded.
pulleys drives where multi-step operation is
obtained by changing the length of the belt 3.16 All gears and sprockets wherever located shall
shall be guarded. be guarded adequately.
c. Every V-belt and pulley drive including V 3.17 Friction drives located 2 100 mm or less above
belt and step-cone pulley drives, any part of floor or other working level shall be guarded.
which is 2 100 mm or less above the floor or
working level shall be enclosed. 3.18 The chains, sprocket and chain drives, located
with 2 100 mm of the floor or other working
d. If the bottom of the guard is within 100 mm level, shall be guarded.
of the floor or supporting structure, the
bottom of the guard need not be enclosed. 3.19 Where workmen pass under the chain drives, a
shallow trough or other effective means of
e. Where a group of flat belt drives is guarded sufficient strength to carry the weight of a
by a standard railing guard, such drives broken chain shall be provided.
shall be considered guarded where the
distance from the vertical plane of the rail to 3.20 Manually operated power disconnecting devices
the nearest point of any belt or pulley is not shall be designed, constructed and installed that
less than 380 mm nor more than 500 mm
18
CHAPTER 3- POWER TRANSMISSION EQUIPT., PRIME MOVERS,
MACHINES AND MACHINE PARTS
they will remain in the neutral position until 4.11 Exterior shapes or any part of the machines that
intentionally actuated. require frequent contacting or handling should
be so designed as to facilitate convenience in
3.21 Machine Guarding Other Than Point-of- handling, while moving parts that cannot be
Operation: enclosed should, as far as possible, be smooth
in contour.
Relates to the belts, pulleys, gears, shafts and
shafts ends, screws, projections, and all other
Table 3.4
moving machine parts, other than at the point- Threshold Limit Values for Noise Exposure
of-operation, that constitute potential injury
producing conditions. Max. Sound Levels (Slow
Hours of exposure per day, Hrs.
Response), dB
Section 4.0 Principle of Safe Machine 8 90
6 92
Design: 4 95
3 97
4.1 Dangerous moving parts should be enclosed. 2 100
1% 102
I 105
4.2 Parts subject to wear, adjustment, and hand % 110
lubrication should be conveniently accessible. 1/4
115*
*ceiling Value. No exposure in excess of 115 dB is allowed.
4.3 Lubrication should wherever possible be
automatic and continuous when the machine is 4.12 Weight of parts to be handled should be kept
in operation. within the limits at convenience and safety, or
these parts should be so designed that they may
4.4 Consideration should be given to individual drive be conveniently handled by mechanical means.
so that hazards due to driving mechanism may
be minimized. 4.13 Throughout the design of the machine and its
parts, consideration should be given to
4.5 Sharp lighting, contrasts between light and convenience in attaching accessories,
shadow and glare in the vicinity of the point of particularly point-of-operation guards for moving
operation should be avoided. Color contrast parts. In essence, bosses for accessories may
should be considered, as well as the provision of be cast on the framework of machines in such a
integrally mounted lights, and the most effective way as to permit drilling, tapping, and the bolting
probable position of independent lighting units. on of accessories without weakening the
structure of the machine itself.
4.6 Materials should be mechanically conveyed to,
and products from machines wherever possible. 4.14 Consideration in design should be given to the
external shape of the machine so that danger of
4.7 Provision should be made for automatically accident from tripping, falling and collision will
conveying dusts and gases away from a be minimized. Splay-footed supports, for
machine. example, that stand out from the body of the
machine sometimes cause a tripping hazard.
4.8 Noise should be eliminated or reduced to no Corners may often be rounded to lessen the
more than the maximum allowable according to danger from accidental contact.
the table of threshold limit values for noise
exposure. Similarly, employee exposure to such 4.15 Liberal factors of safety should be used in
noise shall be limited according to Table 3.4. determining the strength of parts.
4.9 Vibration should be eliminated or reduced to the 4.16 Wherever manufacturing circumstances permit,
maximum permissible extent. point-of-operation guards should be installed by
the builder of the machines so that it may be
4.10 Machine motions tiring to the eyes should be delivered to the purchases in a fully guarded
avoided, as when reciprocating or revolving condition.
parts must be viewed through cross screens or
lattice-work. 4.17 Consideration should be given to the safe
location or isolation of machines that cannot be
made safe otherwise.
19
AND MACHINE PARTS
CHAPTER 3- POWER TRANSMISSION EQUIPT., PRIME MOVERS, MACHINES
r minute (RPM);
or
P = power transmitted in kW;
(4b) D =‘s/1.755x 106 P
S = allowable torsional shearing stress in
kPa
For lineshafts carrying pulleys:
T = torsional or twisting moment in N-m; N
3
D
(5a) P
1.738x 106
4, = polar section modulus in m
3 (see
Table 3.5.1)
or
The maximum allowable torque or twisting D= 17 3
l.
8x1O
\J 6P
(5b)
moment, Tmax for shaft of any cross-section is:
TmaxSsXZp (1)
For small, short shafts:
(6a) P= N
3
D
For a shaft delivering P kilowatts at N revolutions 0.837x 106
per minute the twisting moment I Newton-meters,
or
Tbeing transmitted is:
(2a) (6b) D= \.JO.837xlO6P
3
T=9,55
P ;
x10
N
N
20
CHAPTER 3- POWER TRANSMISSION EQUIPT., PRIME MOVERS, MACHINES AND MACHINE PARTS
Illustrative Example: What horsepower would a fiber. This method may be used to find the
short shaft, 50.8 mm in diameter, carrying but two approximate value of the polar section that
pulleys close to the bearings transmit if the shaft are nearly round. For other than circular
makes 300 revolutions per minute? Using cross—sections, however, the polar section
Formula (6a) modulus does not equal the polar moment
of inertia divided by the distance c.
P = (50.8) x 300 = 46.99 kW
0.837x 106 5.2 V-Belts and Sheaves. The tapered cross-
sectional shape of a V-belt causes it to wedge
Table 3.5.1. firmly into the sheave groove during operation
Polar Moments of Inertia and Polar Section Module so that the driving action takes place through the
sides of the belt rather than the bottom, which
Sectbn rMoment cThert% Po%erSenMoths normally is not in contact with the sheave at all.
21
CHAPTER 3— POWER TRANSMISSION EQUIPT., PRIME MOVERS, MACHINES AND MACHINE PARTS
c. Measuring a Multiple V-Belt. The pitch of the sheaves without injury. Also shown in
multiple V-belts is determined by measuring Table 3.5.4 is the minimum allowance above
fixture consisting of two equal diameter the standard center distance (plus values)
sheaves having standard grooves and for which the centers should be adjustable
pulled with a standard test load indicated in to take up any slack in the belts due to
Table 3.5.2. One of the sheaves is fixed in stretch and wear.
position, while the other is movable along a
graduated scale with the specified tension Table 3.5.4 Minimum Center Distance Allowances
applied to it. for Installation and Take-up of Multiple V-Belts
total tension between the two strands of the 38 to 60 -19, +38 -25, +38 -38, +38 - -
belt. The pitch length is the length obtained 60 to 90 -19, +51 -32, +51 -38, +51 - -
by adding the pitch circumference of one of 9Oto 120 -25, +64 -32, +64 -38, +64 - -
120 to 158 -25, +76 -32, +76 -38, +76 -51, +76 -
the measuring sheaves to twice the 158to 195 - -32, +89 -51, +102-51, +102-64, +102
measured center distance between them. 195 to 240 - -38, +102 -51, +102 -51, +102 -64, +102
Deviation of the measured pitch length from 240to270 - - -51,+114-64,+114-64,+114
270to330 -51+127-64+127-76+127
the standard pitch length shown in Table - -
-51,+152-64,+152-76,+152
330to420
ould be within the tolerance limits
-
-
over
All dimensions in mm.
*AlIow + values to be 1.5 per cent of belt length above
The grooves of the measuring sheaves
standard center distance for stretch and wear.
should be machined and maintained to the
following tolerances: pitch diameter, ±0.002
e. Selection of Multiple V-Belts. The charts
inch; groove angle, +0 degrees, 2ominutes;
on Figure 3.5.1 appears in Engineering
and groove top width, ±0.002 inch.
Standards for Multiple V-Belt Drives enables
a V-belt of appropriate type to be selected
c. Belt Length and Center Distance. The
for a given RPM of the small sheave, the
relation between center distance and belt
transmitted power of the driving unit, and the
pitch length is given by the following
service factors are known. The selection
formula:
procedure follows:
22
CHAPTER 3- POWER TRANSMISSION EQUIPT., PRIME MOVERS, MACHINES AND MACHINE PARTS
f. Power Rating for Multiple V-Belts. The g. Arc of Contact. The arc of contact made by
following formulas and accompanying table the V-belt on the small sheave is of
of constants (Table 3.5.6 to 3.5.9) may be importance when computing the power
used to determine the general horsepower rating of a V-belt for a give drive. This may
rating of a single V-belt. The total be found by the formula:
transmitted power through multiple V-belts
thus, shall not exceed the sum of individual Arc of Contract = 180° (D - — d) 60° (5)
rated capacities of all connected V-belts. C
The recommended power, P which may be where D, d and C are as noted above.
transmitted through a single V-belt for a Correction factors for various arcs of
specified belt speed, S is given by: contact, used in finding power capacities of
multiple V-belts drives (see example) are
P = (0.17) x S°
’
9 — (3.731)YS— 0.0057Z S
3 given in Table 3.5.8.
(3) d
h. Speed of Operation. V-belts operate most
where X, V and Z are factors based on the efficiently at speeds of about 23 meters per
quality of the belt used (Table 3.5.6); d 9 = second. For belt speeds of 25 meters per
equivalent diameter of small sheave which second and more the sheave should be both
is equal to pitch diameter multiplied by small statistically and dynamically balanced.
diameter factor (Table 3.5.7); P = the Speed design and materials may also be
recommended power in kW; and S linear called for and the belt manufacturer should
belt speed in meters per second (mps), or be consulted.
0
-J
-J
A.C. D.C.
800
700 . Syn-
0 600 Squirrel Cage Single
500 chronou
U.
0 Phase
400
300 7-- /
200 Z7 I—--- Applications
2
S
‘
‘ &
/
100 -
2
-
3
-z
5 67191
810
20 30 40 160 ‘80 100 100 300 500
ew
.E
_j
o.
1()
.
X
0(I) E .
Z
507090 400
HORSEPOWER X SERVICE FACTOR 0
Paddle-
Table 3.5.7 Small Diameter Factors Propeller 10 10 12
Range of Speed Ratio Small Diameter Factor Liquid
1.000— 1.019 1.00 Semi-Liquid 1.2 tO 14 12 - - - -
1.020—1.032
- - -
1.223 1.274 —
1.08 Mixer - 1,2 1.6 1.4
1.275—1.340 1.09 Granulator 1.2 1.6
- 1.4
1.341—1.429 1.10 Dry Press - 1.2 1.6 1.4 - - - - - - -
¡%
23
CHAPTER 3- POWER TRANSMISSION EQUIPT., PRIME MOVERS, MACHINES AND MACHINE PARTS
Compressors 1 2 1 2 1 4 1 4 1 2
Centrifugal — — — — — Table 3.5.7 Length of Correction Factors
Rotary 1.2 1.2 - 1.4 1.4 - 1.2 1.2 1.2 - -
Length A I B I C
lor2Cyl. 1.4 1.4 1.5 1.5 - 1.2 - - Designation Correction Factor
Conveyors 1.6 26 0.81 - -
Apron — — 31 0.84 - -
1 2 1 4
Sand) ..
35 0.87 0.81 -
- 1 0 1 1 -
Package) — —
42 0.90 0.85
1. Chain Pitch: Distance in mm 46 0.92 0.87 -
48 0.93 0.88
between centers of adjacent joint
-
24
_
CHAPTER 3- POWER TRANSMISSION EQUIPT., PRIME MOVERS, MACHINES AND MACHINE PARTS
25
CHAPTER 3— POWER TRANSMISSION EQUIPT., PRIME MOVERS, MACHINES AND MACHINE PARTS
26
CHAPTER 3- POWER TRANSMISSION EQUIPT., PRIME MOVERS, MACHINES AND MACHINE PARTS
The data for each size of chain are divided Table 3.11 Horsepower Ratings for Roller Chains Drive
into four zones. The first is for Type I
lubrication; the second, Type II lubrication; 1/2 Inch Pitch Standard Single-Strand Roller Chain No. 40 —
and the fourth; for Type IV lubrication, as No.of Revolutions per Minute Small Sprocket —
the right of the boundary line shown. 11 — .23 0.80 1.50 2.16 3.11 4.03 4.66 3.03 2.17 1.72
13 .28 t196 1.80 2.59 3.73 4.83 5.99 3.89 2.79 2.21
15 .32 1.12 2.10 3.02 4.35 5.64 7.43 4.82 3.45 2.74
Type I. Manual Lubrication: Oil is 17 .37 1.29 2.40 3.45 4.98 6.45 8.96 5.83 4.17 3.31
applied periodically with a brush or spout 19 I .42 1.45 2.71 3.90 5.62 7.27 10.5 6.88 4.92 3.91
21 .46 1.62 3.02 4.34 6.26 8.11 11.7 7.99 5.72 4.54
can, preferably at least once every 8 23 .51 1.78 3.33 4.79 6.90 8.94 12.9 9.16 6.55 5.20
hours of operation. Volume and frequency 25 .56 1.95 3.64 5.24 7.55 9.78 14.1 10.4 7.43 5.89
should be sufficient to prevent 0.68 2.38 4.43 6.38 9.20 11.9 17.2 13.6 9.76 7.75 IV
33 0.81 2.80 4.24 7.54 9.20 14.1 20.3 17.2 12.3 9.76
discoloration of lubricant in the chain 40
—
0.93 3.24 6.05 8.71 12.5 16.3 23.4 21.0 15.0 11.9
joints. 45 1.06 3.68 6.87 9.89 14.2 18.5 26.6 25.1 17.9 14.2
50 1.18 4.12 7.70 11.1 16.0 20.7 29.8 29.4 21.0 16.7
55 1.31 4.57 8.53 12.3 17.7 22.9 33.0 33.9 24.2 19.2
Type II. Drip Lubrication: Oil drops are 60 1.44 5.02 9.37 13.5 19.4 25.2 36.3 38.6 27.6 -
Teeth
Small
I 50 I 100 200 500 I 700 I 900 1200 1400 1600 I 1800
Type IV. Oil Stream Lubrication: The Sprkt. Horsepower Rating
lubricant is usually supplied by a 11 0.78 1.44 2.69 6.14 8.32 10.5 11.9 9.45 7.70 6.49
13 093 1.72 3.22 7.34 9.96 12.5 15.30 12.10 9.89 8.34
circulating pump capable of supplying 15 1.08 2.01 3.76 8.57 11.0 14.6 18.9 15.0 12.3 10.3
each chain drive with a continuous stream 17 1.24 2.30 4.31 9.81 13.3 16.7 21.7 18.2 14.8 12.5
of oil. The oil should be applied inside the 19 I 1.40 2.60 4.86 11.1 15.0 18.8 24.4 21.5 17.5 14.70
21 1.56 2.89 5.41 12.3 16.7 21.0 27.2 24.9 20.3 17.10
chain loop evenly across the chain width, 23 1.72 3.19 5.97 13.6 18.4 23.2 30.0 28.6 23.3 19.6
and directed at the lower strand. 25 1.88 3.49 6.53 14.9 20.2 25.4 32.9 32.4 26.4 22.5
30 2.29 4.25 7.95 18.1 24.6 30.9 40.0 42.6 34.7 29.2 IV
33 2.70 5.02 9.40 21.4 29.0 36.5 47.3 53.6 43.7 36.9
Consult chain manufacturers when it
—
40 3.12 5.80 10.90 54.7 33.5 42.1 54.6 62.7 53.4 45.0
appears desirable to use a type of 45 II 3.55 6.90 12.3 28.1 38.1 47.8 62.0 72.2 63.7 53.7
lubrication other than that recommended. 50 3.97 7.38 13.8 31.5 42.7 54.0 69.5 80.0 74.6 62.9
55 4.40 8.18 15.3 34.9 47.3 59.4 77.0 88.4 86.1 72.6
60 4.84 8.99 16.8 38.3 51.9 65.3 84.6 97.2 98.1 82.7
The extreme right portion of the tabulated
data is shown in boldface. This represents
ratings in the galling range. For optimum
results, it is recommended that the roller
chain manufacturer be given the
opportunity of evaluating conditions of
operation if these horsepower ratings apply.
27
CHAPTER 3- POWER TRANSMISSION EQUIPT., PRIME MOVERS, MACHINES AND MACHINE PARTS
11/’ Inch Pitch Standard Single-Strand Roller Chain No. 100 (Cont.
—
f Revolutions per Minute Small Sprocket
—
Ff Revolutions per Minute — Small S rocket 19001100011 1oc412ocl11300114001150011600117001 1800 I 1900 120001
11000111001120011 300I140011600I1800j2000122OC2400125001 2600 I SnrI Horsepower Rating
Sork Horsepower Rating 11 37.8 27.1 3116.4 14.8 13.4 12.2 11.2 10.4 9.60
11 III 23.4 114.2 11.6 9.71 8.30 7.20 6.30 5.90 5.60 13 40.8 34.9 .5j21.0 19.0 17.2 15.7 14.4 13.3 5.20
13 30.1 ‘18.2 14.9 12.5 10.6 9.20 8.10 7.60 -
15 50.6 43.2 i[2’.1 23.5 21.2 19.5 17.0 16.5 -
28
CHAPTER 3- POWER TRANSMISSION EQUIPT., PRIME MOVERS, MACHINES AND MACHINE PARTS
r
2— mcli Pitch Single-Strand Roller Chain No. 160
—
I 10 I 25 I
50 looIlSol200l25oI300I35oI 400 I 450 500 I Horsepower Rating
sg, Horsepower_Rating 11 3.07 7.02 13.1 24.4 35.1 45.5155.6 65.5 75.3 84.9 94.8 96.6 III
11 - 2174.8 9.06116.9 4.4 31.5 38.6 45.5 522 58.9 65.5 720 13 3.67 8.42 15.7 29.2 42.0 54.4166.6 78.4 90.1 102 113.3 124
13 2.5 10.9120.3 9.2 37.8 46.2 54.5 62.5 70.5 78.4 86.2 15 4.28 9.86 18. 34.1 49.0 63.5177.7 91.5 105 119 131 145
15 2.9C 12.7 23. 34.1 44.1 54.0 63.6 73.1 82.4 91.6 101 17 4.90 11.2 20. 39.0 56.1 72.7188.9 105 120 136 150 167
I
17 14.5 27. 50.5161.71 P 83.6 942 105 115 19 .5312.723. 44.a63.282.oI100 118 136 153 170 188
19 3.8 180 30. ,j70.Gi t.1 94.3 106 118 130 21 .16 14.1 26. 49.0 70.5 91.41112 132 151 171 189 209
21 4.2 18.2 34.C 3.4 776 91.4 105 118 132 145 23 .80 15.6 29. 54.1 77.7 jjJj23 145 167 188 208 231
23 4.7’ 20.1 37.t 0.0 85.6 101 116 131 145 160 25 7.44 17.1 31. 85.1 135 159 183 206 228 257
25 5.1 22.0 41.1-
6.6 93.7 110 127 143 159 175 30 .06 20.2 38.7 ‘2. 104 134 164 193 212 251 277 307
30 a’—
62 50f
7 - 114 134 154 174
‘“ 194 213 IV 33 0.724.545. 122 159 194 228 263 296 338 363
.
33 7.4a, 31.6I5.1
,.. 110 135 159 182 206 229 251 40 2.4 28.3 52.t 141 183224 264 304 342 380 410
40 .59 3T.2 127 156 183 211 238 264 290 45 II 4.0 30.1 59.9 111 160 20j 254 300 345 389 430 421
.76 41.5 77.5 112 144 177 208 239 270 300 330 50 5.736.067. 125 180 23285 336 386 439 453 424
II 55 17.4 40.0 74.4 139 199 258 316 372 405 483 455 418
50 10.9]24.9 46.5 86.8 125 162 198 233 268 302 336 370
55 12.1127.6 51.5 96.2 139 179 219 259 297 335 372 362 60 9.1 43.9 81.8 152 219 284 347 409 4151 484 449 403
60 13.3130.456.6 106 152 197 241 284 326 368 396 329
/4 Inch Pitch Standard Single-Strand Roller Chain No. 140 (Cont.) 2inch Pitch Standard Sinale-Strand Roller Chain No. 160 (Cont.)
—
—
Teeth 550 1600 1700 1800 1900 11 000111001120011 3001 1400 11500 1600 I omal
: Horsepower Rating
11
Horsepower Rating
J1 73.5 65.2 58.3152.6 47.7 43.6 40.0 34.1 29.6 26.0 23.0
11 III 75.1165.8 52.4 42.9 35.9J_ 26.6 23. 20.7118.5 167 15.2
13
-
13 [108 94.4 83.7 74.9j67.5 61.3 56.0 51.4 43.9 38.0 33.4 18.4
93.9 84.6 67.3 55.1 46.21 34.2 30. 26.6 23.8 21.5 10.8
15 105 83.4 68.3 57.2E 42.4 37. 33.0 29.5 26.6
15 [i 117 103 92.8183.7 76.0 69.4 63.7 54.4 47.1 41.4 7.4
-
17 [161 141 125 1121101 91.7 83.7 76.8 65.6 56.9 42.8
17 126i100 82.4 69.11 51.144 39.8 35.6 24.0 -
-
30 F 330 293 262 236 215 196 168 90.7 4.7 - -
40
- - -
- - - -
45 392 356 315 269 217 161 101 37.3
45 349 387 381 308 221 120 7.8 - -
Lc
- - - - - - -
[ = ft/mm x .00508
29
CHAPTER 4- MACHINERY DANGER ZONE AND POINTS OF OPERATION
Chapter 4
interpreted as alternatives to those described in other the front or sides of the point of operation which is
chapters of this code. interlocked or connected to a tripping device which will
prevent operation of the machine until the hand or
hands of the operator have been removed from the
danger zone.
Section 2.0 Definitions
Plate Shear — machine capable of shearing metal
Danger Zone and area of place near or at the point
—
stock rolls clean and assist in feeding stock into the in- Power Press — motor-driven machines fitted with
running or feed rolls on the machine. It usually rams or dies for purposes of blanking, trimming,
consists of curved steel plates mounted in front of, and drawing, punching, stamping, forming or assembling
leading to each pair of rolls. This plates extends materials.
throughout the length of the rolls with its concave side
toward the rolls and its opposite edge held by spring or Pull-Out Protective Device (Hand Fed). A
gravity action against the surface of the top rolls. mechanically operated device attached to the
operator’s hands, wrist or arms which withdraws the
Drop Hammer a heavy metal cylinder or hammer
—
operator’s hands from the danger zone as the ram
which is raised a practicable height and dropped so descends.
that the force or energy of the blow is developed
entirely from gravity. Ram — the reciprocating machine part within a
cylinder. It may also be called plunger, slide or
Foot and Hand Press machines actuated by foot or
—
mandrel.
hand power only, and fitted with rams or dies for
purposes of blanking, trimming, drawing, punching, Sweep Guards a mechanically operated guard that
—
stamping, forming or assembling cold worked sweeps the hands of the operator out of the way of the
materials. descending ram.
30
CHAPTER 4- MACHINERY DANGER ZONE AND POINTS OF OPERATION
31
between the
b. Photoelectric Guard systems may consist of material being cut exceeds 10 mm.
beams of light over the perimeter of the
danger zone. When such beam is broken or c. If the material to be cut is in the form of
blocked by any part of the operator’s body, angles: i.e. T-bars, Z-bars, or other section
an emergency stop mechanism is actuated. where the guard may not satisfy the
requirements of Section 4.3.6-a. and 4.3.6-
c. Squaring shears guarded by means of strips b; the saw may be covered with a
of heavy metal in front of the knife should be horizontally sliding guard, or an enclosure
set at such an angle so that the knife cutting with an opening through which the stock
line will be visible to the operator. may be fed.
The non-repeat device may not be rendered a. The in running side of the rolls shall be
inoperative unless proper instruction and provided with a fixed or self-adjusting barrier
authorization is given by the employer to the so arranged that the material can be fed to
operator in order to permit continuous operation the rolls without permitting the fingers of the
of the press. Suitable fixed guards, warning operator to be caught between the rolls or
devices and signs shall be provided whenever between the guard and the rolls.
the press is in continuous mode.
b. The control device shall be of the constant
I
3.5 Treadle Guards (Class A). A treadle on every contact type and shall be so located as to
foot controlled power press shall be protected by prevent the employee from contacting the
means of a guard designed to prevent danger zone, or
accidental tripping. For treadles other than long
bars extending across the machine, the c. The prime mover shall be equipped with an
openings in such guards shall not be more than effective brake and there shall be installed
twice the width of the foot. across the front of the rolls at approximately
knee height a control bar, lever, or other
3.6 Circular Metal-Cutting Saws (Class B): device which when actuated will stop the
motor and apply the brake.
a. Circular metal-cutting saws shall be
provided with a hood that will cover the saw 3.8 Bar Stock Machine (Class A). On machine
to at least the depth of the teeth. The hood where revolving bar stock is being machined,
shall automatically adjust itself to the that portion of the bar stock which extends
thickness of stock and remain in contact beyond the machine shall be guarded by a
with the material being cut at the point trough or tube or by other effective means.
where the saw engages the stock.
3.9 Wire Drawing Machines (Class B)
b. There shall be a provided fixed or manually-
adjusted hood or guard when the space a. Blocks shall be equipped with a stopping
device so arranged that it will automatically
32
CHAPTER 4- MACHINERY DANGER ZONE AND POINTS OF OPERATION
shut down the machine in case the operator 3.14 Drop Hammers: Drop hammers shall be
should be caught on the block and be equipped with safety stops which will hold the
carried around it, or hammer in the elevated position. Such stops
shall be of the pivoting type and shall be of such
b. A device along the operating side of a a design that requires the hammer to be lifted to
continuous drawing frame or unit so release the safety stops.
designed that pressure against the device
will instantly initiate the process of stopping Section 4.0 Die Casting Machines
sequence of the machine.
4.1 Hot Chamber Machine Controls. Every hot
c. Reels shall be equipped with stopping chamber die casting machine shall be equipped
device so arranged that it will automatically with one of the following controls:
shut down the block in case the operator
should be caught in the wires as it runs from a. Two-hand controls requiring the
the reel, or in case the reel should be drawn simultaneous use of both hands until the die
up to the frame. is completely closed. Removal of either or
both hands during the closing of the die will
3.10 Planners (Class A). Openings in the bed of all stop or reverse the closing cycle, or
metal planners shall be covered with substantial
metal or other suitable covering. b. A single control of the constant pressure
type. This control shall be located at such a
3.11 Alligator Shears (Class B): distance from the parting line of the die that
the operator cannot reach into the die at the
a. The upper jaw of the shear shall be parting line with his free hand. Removal of
surrounded with a heavy U-shaped metal the hand from the control during the closing
strip with the lower edge of the strap just far of the die will stop or reverse the closing
enough above the cutting edge of the fixed cycle, or
jaw to allow the material to be inserted
under it. The clearance from the moving jaw c. A sliding gate guard which when closed will
shall not be over 76 mm, the width of the bar prevent contact by the operator and the die.
should be great enough so that the tip of the This gate shall be interlocked with the
moving jaw does not rise above it. control system so that if the gate is opened
prior to the completion of the closing cycle,
b. A horizontal bar shall be secured to the the closing cycle will stop or reverse.
lower jaw, parallel to the cutting edge, at a
height sufficient to permit the passage of the 4.2 Cold Chamber Machine Controls. Every cold
thickest stock, and so positioned to prevent chamber die casting machine shall be equipped
stock from bending or flying upwards. with one of the following controls:
3.12 Abrading, Buffing and Polishing Machines a. Two-hand controls requiring the
(Class A): simultaneous use of both hands until the die
is completely closed. Removal of either or
a. Exposed arbors shall be guarded. both hands during the closing of the die will
stop or reverse the closing cycle;
b. Arbor ends which are not equipped with a
coarse nuts or equivalent shall be guarded. b. A single control of the constant pressure
type. This control shall be located at such a
3.13 Tumbling Barrels (Class A) distance from the parting line of the die that
the operator cannot reach into the die at the
a. Tumbling barrels shall be completely parting line with his free hand. Removal of
enclosed or guarded by movable rail guards, the hand from the control during the closing
or by other suitable and effective means. of the die will stop or reverse the closing
cycle;
b. If enclosed, tumbling barrels shall be
equipped with an effective lock or brake c. A sliding-gate guard which when closed will
mechanism. prevent contact by the operator and the die.
This gate shall be interlocked with the
33
CHAPTER 4- MACHINERY DANGER ZONE AND POINTS OF OPERATION
control system so that if the gate is opened control during the closing of the die will stop
prior to the completion of the closing cycle, or reverse the closing cycle.
the cycle will stop to reverse:
4.5 Plunger Control:
d. Two-hand controls requiring the
simultaneous use of both hands until the die a. Every plunger on hot chamber machines
is within 50 mm of complete closing. This shall be equipped with a control interlocked
control shall have an interlocked limit switch with the die which will prevent the operation
that maintains a closed circuit for the last 50 of the plunger prior to the closing of the die.
mm of the closing cycle. Removal of either
or both hands before the activation of the b. Every plunger on cold chamber machines
limit switch will stop or reverse the closing shall be equipped with a control interlocked
cycle. with the die which will prevent the operation
of the plunger unless the die is completely
4.3 Ladling Operation. To activate the plunger in open or completely closed. Or for the
the shot sleeve a single control shall be removal of a stuck plug, a cold chamber
provided. This control shall be a type which machine may be equipped with two-hand
permits the operator to use his free hand for controls, which operate the plunger and
ladling metal. The push button control shall be require simultaneous use of both hands.
so guarded by a shield or recessed so that it
cannot be activated by any part of the body 4.6 Shields Between Die Casting Machine.
other than the finger. Shields shall be provided between die casting
machines to protect against metal spitting.
4.4 Hot and Cold Chamber Machines, Helpers These shields shall be located at the parting line
Protection. Where a helper is employed, his of the die and shall be no less than 1 200 mm
position shall be protected by: wide and 1 830 mm high.
a. A fixed-barrier guard with controls. The 4.7 Holding Furnaces. Any open holding furnace,
control may be foot-operated and shall be which measures less than 750 mm from the floor
interlocked with the primary control so that or working level to the furnace top shall be
the machine cannot be started while the guarded by means of a ring guard around its
secondary control is activated. If the perimeter to a height of at least 750 mm from
secondary control is activated during the the floor or working level.
closing cycle, the closing will stop or
reverse; or Section 5.0 Wood Working Machine
b. A sliding-gate guard which when closed will 5.1 Circular Rip Saw (Class B) Manual Feed:
prevent contact by the helper and die. This
gate shall be interlocked with the primary a. A hood shall be used that will cover the saw
control system so that the machine cannot to at least the depth of the teeth.
be started while the gate is opened and
cannot be started until it is closed; or b. Such hood shall automatically adjust itself to
the thickness of and remain contact with the
c. Two-hand controls connected with the material being cut around point where the
primary controls and requiring simultaneous stock encounters the saw; or
use of both hands of the helper before the
machine can be started. Removal of one or c. The hood may be a fixed or manually
both hands during the closing cycle will stop adjusted hood or guard provided the space
or reverse the closing cycle; or between the bottom of the guard and the
stock does not exceed 12.70 mm.
d. A single control of the constant pressure
type connected with the primary controls. d. The hood or other guard shall be so
These controls shall be located at such a designed as to prevent a kick-back. “Anti
distance from the parting line of the die that Kick-Back” devices shall be designed to be
the helper cannot reach into the die with his effective for all thickness of material.
free hand. Removal of the hand from the
34
CHAPTER 4- MACHINERY DANGER ZONE AND POINTS OF OPERATION
b. The feed rolls or star wheels shall be 5.4 Cordwood and Similar Saws (Class B). All
enclosed with a cover coming down to within unused portions of the saw blade shall be
12.70mm of the stock. guarded.
c. A spreader shall be fastened securely at the 5.5 Box Shock Cut-Off Saws (Class B). Box shock
rear of the saw in alignment with the saw cut-off saws shall be guarded either by a hood
blade, except where a roller wheel is or splitter-type guard. Either type guard shall
provided at back of saw. The spreader shall cover the top back quarter of the saw and shall
be slightly thinner than the saw kerf, and be kept adjusted close to the saw.
slightly thicker than the saw disc.
5.6 Swing Cut-off Saw (Class A)
d. The exposed parts of the saw blade under
the table shall be guarded. a. The saw blade shall be encased on both
sides in such a way that at least the upper
e. Every self-feed circular ripsaw shall be half of the blade and the arbor end will be
equipped with an anti-kick-back device completely covered.
installed on the in-feed side. Such an anti-
kick-back device shall be designed to be b. There shall be an effective device to return
effective for all thickness of stock. the saw automatically to the back of the
table when released at any point of its travel
5.3 Circular Crosscut Saw (Class B): such device shall prevent saw from
rebounding and shall not depend on fiber
a. A hood or guard shall be used to prevent rope or cord for it to function.
contact between the operator and the saw
teeth. c. If a counterweight is used, all bolts
supporting the bar and weight shall be
1. The hood shall automatically adjust provided with nuts and cotter pins. A bolt
itself to the thickness of and remain may be put through the exposed end of the
in contact with the stock nearest the counterweight rod, where the weight does
point where cutting takes place; or not enclose the rod. A safety chain shall be
attached to the counterweight.
2. The hood or guard may be a fixed
or manually adjusted provided the
space between the bottom of the
35
CHAPTER 4- MACHINERY DANGER ZONE AND POINTS OF OPERATION
d. Limit chains or other positive stops shall be d. The cutter blade under the table shall be
provided to prevent the saw from swinging guarded.
beyond the front edge of the table.
5.10 Horizontal Pull Saw (Class A), sometimes
e. Where it is possible to pass behind a swing referred to as “Contractor’s Saw” or “Radial Arm
cut-off saw the rear of the saw shall be Saw” shall be provided with the following:
completely housed when the saw is in back
position. The housing shall include the a. The saw blade shall be encased in such a
swing frame as well as the saw. way that at least the upper half of the blade
and the arbor ends will completely be
5.7 Underhung Swing Cut-Off Saws (Class A). covered.
The saw blade shall be fully enclosed when in
the extreme back position, and the swing frame b. Limit chains or other positive stops shall be
shall not pass the vertical position when at its used to prevent the saw from moving
extreme forward limit. A positive stop shall be beyond the front edge of the table. Such
furnished so that the saw cannot pass the front limiting devices shall be so designed and
edge of the table. located that they can be easily inspected
and they shall be maintained in good
5.8 Portable Power Driven Circular Hand Saws condition.
(Class A)
c. Where a horizontal pull saw is used for
a. Portable circular saw shall be equipped with ripping purposes, there shall be an anti-kick
guards or hood which will automatically back device installed at the in-feed side.
adjust to the work when the saw is in use. Such a device shall be designed to be
The guards are provided so that none of the effective for any thickness and the width of
teeth above the work are exposed to the stock to be cut and shall not be attached
contact; and when the blade is withdrawn to the saw guard. Automatic feeding devices
from the work, the guard shall at least cover when used they shall be guarded.
the saw to the depth of the teeth. The saw
shall not be used without a shoe or guide. d. There should be an effective device which
will return the saw automatically to the back
b. The saw guards shall be equipped with a of the table when released at any point of its
handle or locked or blocked in an open travel; such a device shall prevent the saw
equipped with a handle or lug by which it from rebounding.
may be temporarily retracted without
exposing the operator’s fingers to the blade. 5.11 Band Knives and Band Saws (Class A).
(Including band re-saws having saw blades less
c. Saw guards shall not be locked or blocked than 175 mm in width or band saw wheel less
in an open position and shall be maintained than 1 525 mm in diameter) shall be guarded as
in good working condition at all times. follows:
5.8 Circular Knives (Class A). Circular Knives a. All portions of the saw blade shall be
shall be guarded as follows: enclosed or guarded except that portion
between the guide rolls and the table. The
a. A hood shall be provided to cover the cutting down travel guard from the upper wheel to
edge of the knife. the guide shall be of an angle bar or channel
construction covering the front and at least
b. The hood shall automatically adjust itself to the outside of the blade, and shall be so
the thickness of the stock and remain in adjusted that the blade will travel within the
contact with the stock does not exceed angle bar or channel.
12.70 mm.
b. Band saw wheels shall be fully enclosed.
c. A fixed or manually adjusted hood or guard
may be allowed, provided the space c. Feed rolls of band re-saws and band
between the bottom of the guard and the ripsaws shall be protected with a semi
stock does not exceed 12.70 mm. cylindrical guard to prevent the hands of the
36
CHAPTER 4- MACHINERY DANGER ZONE AND POINTS OF OPERATION
employee from coming in contact with the 5.16 Elbow Sanders (Class A). The revolving head
in-running rolls at any point. shall be fully guarded except where abrasive
comes in contact with the material.
5.12 Jointer (Class A):
5.17 Boring and Mortising Machines (Class A):
a. All jointers shall be equipped with cylindrical
cutting heads. a. Only safety-hit chucks with no projecting set
screws should be used.
b. A suitable guard which will automatically
cover the exposed portion of the cutting b. Boring bits should be provided with a guard
head not engaging the stock shall be used. that will enclose all portions of the bit and
The guard shall be capable of protecting the chuck above the stock.
entire length of the cutting space in the
table. c. The top of the cutting chain and driving
mechanism on chain mortisers shall be
c. The exposed portion of the cutting head at enclosed.
the rear of the fence shall be covered.
d. Where counterweights are used, one of the
d. Where equipped with automatic feed, the following measures, or equivalent means
feeding mechanism shall be guarded. shall be used to prevent the counterweights
from dropping:
e. Where knives are exposed beneath the
table, they shall be guarded. 1. It shall be bolted to the bar by
means of a bolt passing through
Recommendations: both bar and counterweight, or
1. A safety pusher of suitable design should be
provided and used. 2. A bolt shall be put through the
2. The operator must protective eyewear or extreme end of the bar, or
goggles and dust mask during operation of
the machine. 3. The counterweight assembly shall
be equipped with nuts and cotter
5.13 Belt Sanders (Class A). Belt sanders shall pins.
have both pulleys and the unused run of the
sanding belt enclosed. Rim guards will be 5.18 Tenon Machines (Class A). Cutting heads and
acceptable for pulleys with smooth disc wheels saws of tenoning machines shall be guarded.
provided the in-running nip points are guarded.
Guards may be hinged to permit sanding on the 5.19 Planers, Moulders, Stickers and Matches
pulley. (Class A), Shapers (Class B):
5.14 Disc Sanders (Class A). Disc sanders shall a. Knife heads of wood shapers and cutting
have the periphery and back of revolving disc heads of other machines, not automatically
guarded, and the space between revolving disc fed, shall be provided with guards, or
and edge of table shall not be greater than 6.35 templates, jigs, or fixtures which will enable
mm. the part to be processed without exposing
the operator’s hands to the danger zone.
5.15 Drum Sanders (Class A):
b. Single cutter knives in shaper heads shall
a. The exposed parts of the drum except that not be used. Knives shall balance each
portion where the material comes in contact other by weight and shall be so mounted in
with the abrasive surfaces shall be guarded. the heads as to revolve at full speed without
dangerous vibration. The back ends of the
b. Feed rolls and pressure rolls shall be knives shall extend at least to a point where
enclosed except such parts as may be it makes a right angle with the axis of
necessary to feed stock. spindle. When the knife extends a distance
equal to or greater than the gripped length
of the knife there shall be separate means to
secure the knife other than the friction
37
CHAPTER 4- MACHINERY DANGER ZONE AND POINTS OF OPERATION
between the collar and the knife. Such and is so marked. The following table shows
means may be a hook, a through bolt, slots maximum speeds for various diameter saws.
or serrations.
Table 4.5.23 Maximum Operating Speeds of Circluar Saws.
c. Knife heads of automatically fed Pitch Diameter of Saw Max. Circular speed
woodworking machines such as stickers, (mm) (RPM)
5,732
planers, molders, and matchers, shall be 200
4,586
250
guarded against contact. The feed rolls shall 300 3,821
be enclosed, except as may be necessary to 350 3,275
feed stock. The guard shall be fastened to 400 2,866
2,547
the frame carrying the rolls so as to remain 450
2,292
500
in adjustment for any thickness of stock. 550 2,084
Knives shall be so mounted in the heads as 600 1,910
to revolve at full speed without dangerous 650 1,763
700 1,637
vibration. 1,528
750
d. Double-spindle shapers shall be provided 5.24 Wobble Saws. Wobble Saws shall not be used.
with a spindle starting and stopping device
for each spindle. 5.25 Exhaust Systems. Whenever the chips and
sawdust produced by woodworking machines
5.20 Automa ..athes (Shoe Lathes, Spoke and accumulate on the floor so as to endanger
All Other Automatic Lathes of the Rotating employees, suitable exhaust system shall be
Knife Type) (Class A). A hood or cover shall required.
be provided to completely enclose the cutter
blades while the stock is being worked. Such
hood or cover may be of sheet steel and Section 6.0 Paper and Printing Machines
provided with openings no larger than 10 mm in
any dimension. 6.1 Calendar and Similar Rolls (Class B). Each
calendar shall be equipped with a guard or
5.21 Combination Woodworking Machines (Class feeding device, so arranged that the material
B). Each point of operation of all component can be fed without permitting the fingers of the
machines or tools shall be guarded as required operator to be caught by the rolls. The device
for each individual tool in a separate machine. shall be so arranged that the operator can
Such machines shall be equipped with a immediately stop the rolls, at the feed point, by
separate starting and stopping device for each the use of a lever rod or treadle. The rolls shall
point of operation. be equipped with an automatic trip device that
will stop the machine when the fingers approach
5.22 Cracked Saws: the intake points. “Doctor Feed” is acceptable.
a. Any band saw found to have developed a Note: The so-called “Doctor Feed” can be used
crack whose length is greater than one-tenth on calendar stacks. It is a device employed to
(1/10) the width of the band, shall be keep the rolls clean and to assist in feeding the
replaced unless the width is so reduced so material into the in-running side of each pair of
as to eliminate the cracks or unless the rolls on the stack. It generally consists of a
cracked section is repaired. cunied steel plate attached in front of, and
leading to each pair of rolls. This plate extends
b. Any circular saw that is found to have through the length of the rolls with its concave
developed a crack whose length exceeds side toward the rolls and its opposite edge held
5% of the diameter of the saw shall be by spring or gravity against the surface of the
discarded unless the diameter is so reduced top rolls of each pair just above the nip point on
as to eliminate the crack and the tension is the cut-running side.
corrected.
In operation the material is fed into the top or
5.23 Maximum Speeds of Circular Saws. The first pair of rolls of the stack and as it emerges, it
peripheral speeds of circular saws shall not is guided by the curved plate of the doctor feed
exceed 3 600 rn/mm unless the saw has been into the next pair of in-running rolls; and so on
manufactured or hammered for a higher speed down the stack.
38
CHAPTER 4— MACHINERY DANGER ZONE AND POINTS OF OPERATION
6.2 Corner Cutter (Class A). Single and double 6.8 Index Cutter (Class B). All knives or plungers
machines with or without mechanical power used for cutting strips off ends of books and
shall be provided with a guard in front of and to similar operations shall be provided with a guard
the side of knives. that will prevent the operator’s hands from
coming into contact with the cutting knife or
6.3 Corner Stayers (Class A). Corner stayers with plunger as it descends.
or without mechanical power shall be provided
with an automatic device that will instantly stop 6.9 Power-Driven Guillotine Paper Cutters (Paper
the downward motion of the plunger, should the Cutters). Power-driven guillotine paper cutters
fingers of the operator come between the shall be provided with:
plunger and the anvil.
a. (Class A). A non-repeat device that will
6.4 Cutter and Creasers (Class A). Drum cylinder automatically lock the clutch mechanism into
type cutters and creasers shall be guarded so place so that the cutter cannot make a
as to prevent the operator’s hands being caught second stroke until the hand lever is again
between the cylinder and the bed. moved into the starting position, or
6.5 Rotary Scoring Machines (Class A). Scorers b. (Class A). A buffer that will interpose a
shall have guard in front of in-running discs that positive stop to some moving parts of the
will prevent injury to the operator’s hands while machine whenever the clutch fails to
the machine is in operation. perform the function of preventing the cutter
from making a repeat stroke. In addition to
6.6 Drum Winder on Paper Machine (Class A). the non-repeat device or buffer, such paper
Machine should be so arranged that the drums cutters shall be provided with:
run outward. Where the drums run inward on the
operating side a cover or guard shall be 1. (Class B). A-two-handed starting
provided for the point of contact between the device which requires the
drum and the paper roll. simultaneous action of both hands
during the cutting motion of the
6.7 Job Platen Press (Class B). Job platen knife, or
presses with or without mechanical power shall
be provided with one of the following: 2. (Class B). An interlocked starting
device that will interpose a barrier
a. An automatic feed which does not require to interlocking between the starting
the operator’s hands to be placed between levers and clutch which must be
the platen and bed, or released through a movement of the
hand starting lever before the lever
b. An automatic feed which will prevent the can be moved to the position where
platen from closing if the hand or hands of it applies power to the cutter.
the operator are caught between the platen
and the bed, or c. (Class A). Simultaneous operation of paper
cutters by more than one operator shall not
c. A guard or gate, mechanically operated, be permitted or required by the employer.
which will throw the operator’s hands out of
the way as the press closes. For sweep Exception: Continuous feed trimmers.
guards which lift the hands out of the danger
zone, the guard should rise at least 100 mm 6.10 Paper Box Ending and Edge Attaching
above the platen as the press closes, and Machines (Class A). Paper box ending and
should descend by gravity or be drawn by edge attaching machines shall be provided with
springs. The guard shall be so arranged that an automatic device which will prevent the
it will prevent a shear between the guard application of injurious pressure if the fingers of
and the top of the platen, or the operators are between the top of the form
and the pressure head.
d. Any other device or tripping mechanism
which will prevent the platen from fully 6.11 Cylinder and Rotary Presses (Class B). The
closing if the hands of the operator should in-running sides of power-operated rollers or
be between the platen and bed. cylinders shall be provided with a guard so
39
CHAPTER 4— MACHINERY DANGER ZONE AND POINTS OF OPERATION
arranged that the material can be fed to the b. Rotary Slotters. A guard shall be provided
roller without permitting the operator’s fingers to in front of the knives so that the hands of the
be caught between the roller or cylinders. operator cannot come into contact with the
knives while machine is in operation.
6.12 Lithographic Presses (Class A). The in-
running side of the cylinder and roller shall be Section 7.0 Textile and Laundry
provided with a guard that will prevent the Machinery
operator from being caught between the
cylinders. 7.1 Shuttles (Class A). All looms shall have shuttle
guards or shall be constructed in such a manner
6.13 Embossing Machines (Class A). Embossing as to prevent the shuttle from flying off from the
machines of the head type shall be equipped machine.
with:
7.2 Cards (Class A). The cylinder cover or
a. A fixed enclosing front and sides of press revolving flat type cards shall be provided with
with just enough clearance space for an interlock, securely bolted in place; or shall be
feeding stock. The guard shall be so provided with a stripping device so arranged that
arranged that the operator’s fingers cannot the operator cannot come in contact with the
be caught between the press and the die point of operation.
while feeding stock, or
A licker-in cover shall be provided on all cards
b. A fixed or a movable front guard connected and shall be bolted securely in place so that the
to the operating mechanism in such manner operator cannot readily open it. Thumbscrews
that the operator’s fingers cannot be caught or wing nuts shall not be used.
into the press while feeding stock, or
7.3 Carpet Frayer or Rag Shredder (Class A).
c. A two-handed starting device which requires Cylinder door or cover shall be provided with an
the simultaneous action of both hands to interlock so constructed that the cover cannot be
start the machine. opened while the roller is revolving or the cover
shall be clamped in place and the slot be so
Exception: Machines equipped with feeding constructed and guarded that the operator’s
devices such that the hands of the operator fingers cannot come in contact with the roller.
cannot come in contact with the die.
7.4 Carpet Trimmer (Class A). Revolving knives
6.14 Paper Punches and Line Perforators (Class shall be guarded.
B). Mechanical or foot power punches and line
perforators shall be provided with an effective 7.5 Stationary Circular Knife (Class A). Circular
device that will prevent the operator’s fingers Knives or discs shall be equipped with a guard
from coming between the punch and die. that will prevent contact with the cutting edges
while the machine is in operation.
Exception: Paper punches and line perforators
where the clearance between the opening for 7.6 Cotton Picker, Opener and Willower (Class
feeding stock does not exceed 10 mm in the A). The beater cover shall be provided with
open position. interlocking device so arranged that the cover
cannot be opened while the beater is revolving.
6.15 Slotters (Class A):
7.7 Picker Machines (Class A). All machines used
a. Vertical Slotters in picking wool, hair, rags or other material shall
have the rolls completely covered, except the
1. The knife shall be provided with a opening necessary to feed stock. This opening
stripper; or shall be constructed or guarded that the
employee’s fingers cannot come into contact
2. It shall be provided with a guard in with rolls.
front of the knives so arranged that
the hands of the operator cannot 7.8 Pile Cutter or Shearer (Class A). Knife rolls
come into contact with the knives shall be provided with a cover of guard that will
while machine is in operation.
40
CHAPTER 4- MACHINERY DANGER ZONE AND POINTS OF OPERATION
prevent the employee’s fingers from coming in cylinders or shell open during loading or
contact with the rolls. unloading.
7.9 Napper (Class A). Rolls shall be provided with a c. Each washing méchine shall be equipped
cover or guard so arranged that the employee’s with brake or other devices to prevent the
fingers cannot be caught in the rolls while inner cylinder from moving while loading or
feeding the material. unloading.
7.10 Silver and Ribbon Lap Machine (Doublers) 7.15 Centrifugal Extractor (Class A):
(Class A). A device or cover shall be provided
and so arranged that the employee’s hands a. Each extractor shall be equipped with a
cannot be caught under the lap roll. metal cover at least 0.953 mm thick, or its
equivalent sturdiness, which shall entirely
7.11 Garnet Machine (Class A). Openings in the cover the opening to the outer shell. The
lower frame and between lower frames and floor cover shall be kept in its closed position
shall be guarded. Where metal guards are used, when the extractor is in motion.
it shall not be less than 0.953 mm thick.
b. Each extractor shall be equipped with an
7.12 Marking Machine (Class A). interlocking device that will prevent the
cover from being opened while basket is in
a. Each power marking machine shall be motion; and also prevent the operation of
equipped with a spring compression device the basket while the cover is open.
of such design as to protect the finger bones
should these be caught between the Note: This should not prevent the movement
marking plunger and platen, or of the basket by hand to insure an even
loading when the cover is open.
b. The marking machines shall be equipped
with a control mechanism which will require c. No extractor shall be operated at a speed
the simultaneous action of both hands to greater than the manufacturer’s rating,
operate the machine, or which shall be stamped on the basket where
easily visible in letters not less than 6 mm in
c. There shall be a guard that will interpose a height. The maximum permissible speed
barrier in front of the marking plunger. shall be given in revolutions per minute.
7.13 Textile Machines: d. Each engine prime mover individually
driving an extractor shall be provided with
Recommendation: Operators designated to an effective speed limiter or governor.
Blow Room, Spinning, Weaving and part of
Finishing Departments must be provided with e. The exterior of the basket including hoops or
suitable dust masks. Illumination of these bands shall be inspected at least every six
working areas shall be maintained at maximum months to determine condition of basket.
design levels. The extractor shall be dismantled and the
bearings, bearing blocks and basket shall be
7.14 Washing Machine (Class A). inspected at least once a year and all
necessary repairs or replacements made. If
a. Each front loading washing machine shall basket shows signs of weakness, it shall not
be equipped with an interlocking device that be used.
will prevent the inside cylinder from moving
when the outer door on the case or shell is f. Each extractor shall be effectively, secured
open; and it shall also prevent the door from in position on the floor or foundation so as to
being opened while inside cylinder is in eliminate unsafe vibration.
motion.
7.16 Power Wringer (Class A). Each power wringer
b. Each washing machine shall be provided shall be equipped with a guard across the entire
with a safe and effective means for holding front of the feed or first roll so arranged that
the doors or covers of inner and outer when struck the machine will immediately stop.
41
CHAPTER 4- MACHINERY DANGER ZONE AND POINTS OF OPERATION
7.17 Starching Machine (Cylinder or Box Type) a slot or hopper or a rod located directly in front
(Class A). Each starching machine shall have of the feed and extending the full length of the
the rolls or cylinders guarded so as to prevent roll.
contact by the employees while the machine is
in motion. 7.21 Ironer (Flatwork Type) (Class A):
7.18 Drying Tumbler (Horizontal Conventional a. Each flat-work and collar ironer shall be
Type) (Class A): equipped with a guard across the entire
front of the feed or first pressure roles, so
a. Each drying tumbler shall be equipped with arranged that when struck, the machine will
an interlocking device that will prevent the immediately stop.
inside cylinder from moving when the door
on the case or shell is open. Such device b. The pressure rolls shall be guarded or
shall also prevent the door from being covered so that an employee cannot be
opened while the inside cylinders is in caught or pulled into the rolls.
motion.
7.22 Ironer (Body Type) (Class A). Each body
Note: This should not prevent the movement ironer, shall be equipped with a guard across
of the inner cylinder under the action of a the entire length of the feed roll or shoe, so
hand-operated mechanism or under the arranged that when struck, the machine will
operation of an “inching” device. immediately stop.
b. Each drying tumbler shall be provided with 7.23 Ironer (Rotary-body Type) (Class A). Each
adequate means for holding open the doors combined rotary bosom and coat-ironer shall be
or covers of inner and outer cylinders or equipped with a guard across the entire length
shells while being loaded or unloaded. of the feed roll or shoe, so arranged that when
struck, the machine will immediately stop.
c. Each drying tumbler shall be equipped with
brakes or other positive locking devices to 7.24 Ironer (Press Type) (Class A)
prevent the inner cylinder from moving
during loading and unloading. “Inching a. Each ironing press (excluding hand or foot
devices” are permitted. power presses) shall be equipped with a two
hand device which require the simultaneous
Exception: Shakeout or condition!ng action of both hands to operate the press.
tumblers where the clothes are loaded into
the open end of the revolving cylinder and b. Every power-driven ironing press of the type
are automatically discharged out of the used in the dry cleaning or garment
opposite end. manufacturing industry shall be equipped
with two hand controls which will require the
7.19 Shaker (Clothes Tumbler, Batch Type) (Class simultaneous use of both hands to apply
A): heavy pressure or to look the press.
a. Each shaker or clothes tumbler shall be 7.25 Laundry Machine. Working areas around the
equipped with a device that will prevent the Laundry Machine shall be provided with non
tumbler from moving while the door is open. skid or slip-resistant flooring.
The tumbler shall be enclosed or guarded
so as to prevent accidental contact. Section 8.0 Leather and Composition
Good Machines
b. Each shaker or clothes tumbler shall b€
equipped with brakes or other positiv. 8.1 Dinking and Clicking Machrnes (Class A).
locking devices to prevent the insid. Every dinking machine shall be guarded by at
cylinder from moving when the machine least one of the following methods:
loaded or unloaded. “Inching devices” are
permitted. a. “Safety type” dies shall be used throughout.
Dies of this type shall be at least 75 mm in
7.20 Dampening Machine (Class A). The rolls on height provided with safety grooves or
dampening machines shall be guarded by either flanges. This safety flanges reduce the
42
CHAPTER 4- MACHINERY DANGER ZONE AND POINTS OF OPERATION
danger of having the operator’s fingers a simultaneous action of both hands, or they
being caught between top of die and beam. shall be provided with a mechanical feeding
Other types are provided with horizontal or device.
vertical handles at least 65 mm in height
above the die proper; or b. The plunger shall be guarded either by a
complete enclosure or by a barrier guard in
b. The machine shall be provided with a sliding front of the plunger.
table or swinging head which does not
require the operator to place his hands 8.4 Skiving Machines (Roll Feed) (Class A). Feed
under the beam or head; or rolls shall be so arranged that material must be
fed through slot or under a fixed or removable
c. There shall be a two-handed device that metal rod or strip directly in front of the feed and
required both hands of the operator to be running the full length of the rolls.
removed from under the beam at the
moment of tripping the machine or operation 8.5 Splitter (Stationary Knife) (Class A). Feed
of the machine; or rolls shall be so arranged that material must be
fed through a slot or under a fixed metal rod or
d. The point of operation shall be guarded on strip directly in front of the feed and running the
all sides. The end guards shall be fixed and full length of the rolls.
the front and back guards shall be gate
guards of the elevating interlocking type. 8.6 Splitter (Band Knife) (Class A)
8.2 Embossing Machines (Power or Foot Driven) a. All exposed portions of the knife as well as
(Class A). Embossers of the head type shall be band wheels shall be enclosed and feed
equipped with the following: rolls shall be guarded.
a. A fixed guard enclosing front and sides of b. An extension of the stopping device shall be
platen with stock feeding slots too narrow to installed across the entire front of the top of
allow insertion of operator’s fingers, or the feed roll so installed that it can be readily
operated from the operator’s working
b. An interlocking gate-guard connected with position.
the operating mechanism in such a way that
it will automatically protect front and sides of 8.7 Stripper (Class B). Strippers shall be provided
platen during the power stroke in such with control device which requires the
manner that the operator’s hand cannot be simultaneous action of both hands during the
caught by the platen, or cutting movement of the knife.
c. An actuating device that requires the 8.8 Tanning Drums (Class A). Horizontal revolving
simultaneous action of both hands of the drums shall be guarded, in addition, the drum
operator or operators, whenever more than shall be provided with a stopping device, to
one person is required to operate the prevent the movement of the drum while loading
machine. or unloading.
d. A sliding or revolving table or other feeding 8.9 Roll Type Machines (Class A). The in-running
device which does not require the operator side of corrugating, crimping, embossing,
to place his hands under the platen, or pleating, printing, and graining rolls shall be
guarded.
e. A mechanically operated guard that throws
the hands of the operator out of the way as 8.10 Dehairing Machines (Class A). All knives used
the platen descends. Such a guard should in removing hair from hides and skins shall be
be padded to prevent injury should it strike enclosed except such opening as is necessary
the operator’s hand or wrist. to feed stock.
8.3 Heel Compressing Machine (Class A) 8.11 Fleshing and Dehairing Machines Special
—
43
CHAPTER 4- MACHINERY DANGER ZONE AND POINTS OF OPERATION
two hand control. This control must be arranged be so located that the operator
so that the simultaneous and continuous action cannot reach into the mixer while
of both hands is required to set the machine in pressing the button, or
motion.
2. If belt driven, the belt shifter shall be
8.12 Whitening Machines. The moving parts of the so arranged that it will normally
heads of whitening machine shall be enclosed move the belt toward the loose
except such opening as is necessary to feed the pulley and hold it there while the
stock. mixer bowl is tilted and uncovered
unless the operator pushes the belt
lever toward the tight pulley. The
Section 9.0 Food and Tobacco Machinery belt shifter must be so located that
the operator cannot reach into the
9.1 Pressure Bottling Machine (Class A).
bowl while holding the shifter, or
Pressure bottling machines shall be provided
with an enclosure made of sheet metal not less
3. If clutch driven, the clutch lever shall
than 1.27 mm thick or wire mesh with opening
be so arranged that it will move the
not to exceed 6 mm, and shall be so arranged
clutch out of engagement and hold it
on the machine to confine or safety deflect
there while the mixer is tilted or
broken glass. The enclosure shall extend
uncovered unless the operator
downward at sides and rear to a point level with
moves the clutch lever to engage it.
that part of the machine on which the bottle
The clutch lever shall be so located
stands while being filled and upward to a point
that the operator cannot reach into
of at least 100 mm higher than the top of the
the bowl while holding the lever.
bottle and be so constructed that bottle side is
facing the operator. When the bottling is done
Note: When a pushbutton control is
under a pressure of more than 0.053 kg/mm3
be constructed of metal not used, it is recommended that there
such enclosure shall
should be installed in the circuit a
less than 2.799 mm thick.
loose fitting piston type inverse time
relay designed to open the circuit at
9.2 Cake Center (Band Knife) (Class A). Band
the end of one second operation.
wheels of band knives shall be completely
encased and all portions of the knives shall be
Exception: Mechanically fed and
enclosed or guarded except for that portion
discharged horizontal tilting type
between the guide and the table where the saw
dough mixers in inaccessible
engages the stock. If metal guards were used, it
locations.
shall be of not less than 0.953 mm thick; or if
other material is used, the guard shall be of
9.4 Dough, Cakes or candy Mixers (Horizontal
equal strength and rigidity.
Non-Tilting Dough Mixers Type) (Class A).
Horizontal non-tilting type dough mixers shall
9.3 Dough or Candy Mixers (Horizontal Tilting
have a cover with an interlocking device so
Dough Mixer Type) (Class A).
arranged that power cannot be supplied to the
agitators unless the cover is in place on the
a. Horizontal tilting type dough mixers shall be
provided with a cover over the top of the mixer.
mixer. An interlocking device shall be
provided, so arranged that power cannot be 9.5 Dough Brake (Class A):
applied to the agitators unless the mixer is in
a. Rolls on dough brakes shall be guarded so
operating position, with cover in place.
that the operator’s hand cannot come in
contact with the rolls when in motion, or
b. The mixer when tilted shall be operated with
the covers were open.
b. There shall be installed a stop bar located
1. If equipped with an electrical along the end of the dough table which,
pushbutton that will require the when actuated, will automatically shut off
operator to keep his finger on the power and apply a brake to the rolls.
button when operating the mixer
with the cover open; the button shall
44
CHAPTER 4— MACHINERY DANGER ZONE AND POINTS OF OPERATION
9.6 Dividers (Class A): 9.8 Rotary Dough Kneaders (Class A).
a. All pinch points and shear points from a. Each direct-driven rotary dough kneader
reciprocating or rotating parts of the divider shall be equipped with a guard across the
shall be enclosed or guarded, to protect the entire length of the down-running side of
operator’s hands and fingers. each corrugated kneading roll so arranged
and installed that if struck, the machine will
b. Guards at the front of a divider shall be so stop.
arranged that the weight of the dough can
be adjusted without removing the guard. b. All dough kneaders other than those direct-
driven shall be equipped with a guard
c. The back of the divider shall have a across the entire length of the down-running
complete cover to enclose all the moving side of each corrugated kneading roll and
parts, or each individual part shall be shall be equipped with a device which will
enclosed or guarded. The rear cover shall quickly disengage the power. The means of
be provided with an electric switch so operating such a device shall be so located
arranged that the machine cannot operate and so arranged that the operator can
when this cover is open. readily reach it from any working position.
ci. The oil holes in the knife at the back of the 9.9 Slicers and Wrappers (Class A):
divider shall be of such size that employee’s
finger cannot go through the hole. a. Where necessary to manually push the last
loaf through the slicing knives the operator
9.7 Moulders (Class A): shall be provided with, and shall use a
suitable and adequate device by which the
a. Mechanical feed moulder shall be provided loaf can be pushed through the knives
with hoppers so designed and connected to without danger to his hands or fingers.
the proofer that an employee’s hands
cannot go into the hopper where they will b. The cover over the knife head of
come in contact with the in-running rolls. reciprocating blade slicers shall be provided
with an electrical control switch so that the
b. Hand-feed molders shall be provided with a machine cannot operate unless the cover is
belt-feed device or the hopper shall extend in place.
high enough so that the hands of the
operator cannot get into the feed rolls. The c. On slicers with endless band knives, the
top edge of such a hopper shall be well wiring for the motor shall be so arranged
rounded to prevent injury when it is struck or that a brake will be applied each time the
bumped by the employee’s hand. motor is shut off, or it shall be so arranged
by means of a limit switch that cannot be run
c. There shall be a stopping device within easy with the side door open. All doors and
reach of the operator who feeds the molder removable panels to the cutting heads shall
and another stopping device within the be either connected to electric switchers or
reach of the employee taking the dough shall have no latch openings and be so
away from the molder. fastened that they cannot be opened from
the outside through the side door.
d. Where a removable crank is used to adjust
the molder for different sizes of loaf by ci. When it is necessary to sharpen blades on
adjusting a nut on the molder drum, the machine, a barrier shall be provided
brackets shall be provided on the side of the leaving only sufficient opening to the
machine for holding the crank when it is not sharpening stone to reach the knife blades.
in use. The brackets should be connected to
a contact switch so that when the crank is 9.10 Candy Cutter (Roller Type) (Class A). The
removed, the current is broken and the rolls, or knives of roller and fan type candy
machine cannot run unless the crank is cutters, shall be provided with a cover or guard,
returned to rest on the bracket. so arranged that the fingers of the operator
cannot come in contact with same. A safety bar
shall also be provided at the in-feed side.
45
CHAPTER 4- MACHINERY DANGER ZONE AND POINTS OF OPERATION
9.11 Caramel Slitter (Circular Knife Type) (Class cover the hoper opening except for
A). The knives shall be completely covered with openings in the grille and shall be
an adjustable guard of sheet metal or wire mesh above the bottom of the pan.
(with openings not to exceed 6 mm). In addition
there shall be provided a feedbelt to carry the 4. A hinged interlocking grille or
material under and away from the knives, or a grating over the hopper or pan
slide feed set at an incline that will permit the which will open the power circuit
material to pass by gravity against the knives on when the grille or grating is lifted.
the intake side and away from the knives on the Such grilles or gratings shall be
discharge side. designed and located as provided in
item 3 above.
9.12 Nougat Cutter (Class A). A hood shall cover at
least the top half of the knife or disc at all times 5. In large hand-fed grinders of the
and be so constructed that the cutting operation type used in the wholesale or
can be performed without danger to the manufacturing trades, where the
operator. neck exceeds 62 mm diameter and
the opening is not guarded by grilles
or gratings, the distance from the
9.13 Meat, Fish and Other Food Grinders (Class top of the neck to the worm shall be
A): not less than 915 mm and minimum
accessible distance from the
a. Every power driven food grinder of the worm working level to the worm shall not
type shall be so constructed, installed or be less than 2 235 mm.
guarded that eh employee’s finger cannot
come in contact with the worm. b. A pusher shall be provided for each grinder
and shall be used during the feeding
Note: The engineer will accept the following operation where it is possible to increase the
methods as being in compliance with this safety of the operation. Under no
code: circumstances shall a pusher be used in lieu
of the above methods of guarding.
1. A mechanical method of feeding the
worm which will prevent an c. Before cleaning food grinders, the prime
employee from contacting the worm mover shall be disconnected and the
during the feeding operation. controls locked in the ‘off” position.
and spaced not more than 32 mm with boiling water and some chemicals
apart providing the grating is not where carcasses of hogs are placed after
less than 38 mm above the hopper slashing the throat. In most cases, the
rim. scalding tank has no overhead conveyor to
carry the carcasses from the tank to the
Other types of grilles or grating are dehairing machine, instead this is done
acceptable, provided the greatest manually by operator.
dimension in any opening does not
exceed 63 mm and is located no Recommendation: To prevent slipping
less than 115 mm above the worm, hazards, the catwalk surface should be
or more than 115 mm above the made of non skid materials.
hopper rim. Grilles or grating
attached to pans shall completely
46
CHAPTER 4- MACHINERY DANGER ZONE AND POINTS OF OPERATION
47
CHAPTER 4- MACHINERY DANGER ZONE AND POINTS OF OPERATION
provided with an interlocking device which will with a safety trip device by which the
prevent the introduction of the plow into the operator can disconnect the power and stop
• basket until the plate valve has been removed. the equipment in case of emergency.
a. Rolls on all machines, not specifically a. Old Calenders. All calender drives in use of
mentioned, which require the continued contracted for prior to 1985 (the effective
presence of the operator to feed with a year of issuance of this provision),
cover or guard, or irrespective of the size of the rolls, shall be
made capable of stopping within a distance
b. A quick stopping or reversing device, so of no more than 2 percent of the travel from
arranged that the operator can actuate the operating speed. The operating speed shall
device while in his usual working position be measured from the surface of the drive
should hands be caught. roll and expressed in meters per minutes
(m/min). This rule shall apply to calendar
10.7 Soap Presses (Class A). Hand fed presses operating speeds up to 61 rn/mm while
shall be guarded, at point of operation, as running empty.
specified in Sections 4.3.1 and 4.3.4.
Exception: Where operating speeds above
61 rn/mm as measured on the surface of the
drive roll are used, stopping distance of
Section 11.0 Rubber and Composition more than 2% may be permissible subject to
Working Machines engineering determination.
11.1 Calender Rolls (Not Paper) (Class A): b. New Calenders. All new calender drives
purchased or contracted for after 1985 (the
a. Safety devices shall be provided across the effective year of issuance of this provision),
front and back of all calendars extending the irrespective of the size of the rolls, shall be
full length of the face of the rolls and stopped within a distance no more than 1.75
designed to initiate instantly the process of percent of the travel from operating speed.
stopping the calender when either pushed or The operating speed shall be measured
pulled. The device shall not be more than 1 from the surface of the drive rolls and
830 mm nor less than 1 675 mm above the expressed in meters per minute (m!min).
working floor or platform on which the This rule shall apply to operating speeds up
operator stands, and shall be within easy 76.25 rn/mm while running empty.
reach of the operator when he is in normal
working position. Exception: Where operating speeds above
76.25 rn/mm as measured on the surface of
b. On each side of all calendars near both the drive roll are used, stopping distances of
ends of the face of the r’oll, there shall be a more than 1.75% may be permissible
vertical tight wire cable connecting with the subject to written justification by a
bar tripping mechanism. This shall be from professional mechanical engineer. Stopping
the top and fastened to the frame within 300 distances shall be subject to engineering
mm of the floor and at a distance of not less determination.
than 25.4 mm from calender frame.
11.3 Rubber Mills (Class A).
c. At the “bite” of in-running open rolls where
sheeting, duck or other fabric is fed by hand, a. Mills shall be provided with a hopper of such
a safety bar or cable connected to the size and arrangement that it will protect the
stopping device, shall be placed across the operator’s hands against inadvertent contact
full length of the face of the rolls. It shall be with the in-running nip point of the rolls
so located that the operator’s fingers will trip when feeding material, or
the stopping device before coming into
contact with the bite. b. Old Group Mills. For mills driven in groups
of two or more; in use, contracted for, or
d. Calender equipment such as windups, idler constructed prior to 1985 (the effective year
rolls and cooling drums shall be provided
48
CHAPTER 4— MACHINERY DANGER ZONE AND POINTS OF OPERATION
of issuance of this provision), irrespective of b. A bar or other device, connected with the
the size of the rolls, shall be made capable switch, so arranged that the operator’s
of stopping within a distance no greater than fingers cannot reach the worm without first
2% of the travel of the rolls as measured on actuating the switch, or
their surface in meters per minute while
running empty. c. A bar or other device arranged to be
operated by knee, thigh, foot or hand
c. New Group Mills. New mills driven in groups pressure, which will stop the machine.
of two or more; in use, contracted for, or
constructed after 1985 (the effective year of 11.9 Injection Molding Machine (Class A). Every
issuance of this provision), irrespective of the injection molding machine shall be guarded by
size of the rolls, shall be stopped within a any one or more of the following methods:
distance not greater than 1.75% of the travel
of the rolls as measured on their surface in a. By a sliding gate guard so designed and
meters per minute while running empty. installed that it interposes a barrier between
the dies and the operator before the dies
11.4 Bale Cutters — Guillotine (Class A). can close; and shall be so arranged that if
the gate can be opened during the closing
a. All guillotine bale cutters shall be equipped cycle, the cycle will be immediately stopped
with a two hand continuous control, or or be reversed by the opening of the gate.
b. A one-hand continuous control so located that The sliding gate guard shall extend over the
the operator cannot reach the control and the top and to each side of the dies such a
point of operation at the same time. distance so that it would be impossible for
the operator to come in contact with the dies
11.5 Bevel Cutters Circular Knife
— Non-
— while these are closing. The danger zone on
Automatic (Class A). The circular knife shall be the side of the machine opposite the
covered with a metal hood which shall guard the operator’s working position shall also be
cutting edge down to point not more than 12.70 guarded.
mm above the thickest portion of the material
being cut. A positive stop must be provided to b. By two-handed pressure devices or controls
prevent the knife from passing the front edge of which require the simultaneous use of both.
the table. the operator’s hands during the entire die
closing cycle.
11.6 Cuttersheet Rubber (Horizontal Cutter Type)
(Class A). The exposed portion of the knife at 11.10 Thermosettlng Plastic Molding Presses
the sides of the sliding table shall be covered (Class A). Every thermosetting plastic molding
with a metal enclosure so that the operator press shall be guarded by any one of the
cannot come into accidental contact with the methods covered in Section 4.3.1.
knife when feeding the machine. Any holes or
openings on this enclosure, whenever it may be 11.11 Tire Machine. The switch pedal which controls
necessary to have them, shall not exceed 6mm the rotation of the frame while endless piles of
in any dimension. fabric are being adjusted by a bar held in the
operator’s hands must be so connected with the
11.7 Power Driven Rotary Saws and Slitters (Hand brake that removal of pressure from the pedal
Feed) (Class A). A metal hood shall cover the shall stop the machine.
cutting edge to a point not more than 12.70 mm
above the thickest portion of the stock. 11.12 Tube Splicer (Class A). Each tube splicer shall
be equipped with a two-hand control.
11.8 Tubing Machine (Class A):
11.13 Testing and Maintenance (Class A).
a. All hand-fed extrusion machines, including
tubing machines, shall be provided with a. The stopping device on each mill and on
hoppers of such height and size of opening each calendar shall be tested for operation
as to make impossible for the operator’s during each shift. When a group of rubber
fingers to reach the worm, or mills is driven by one motor but stopped by
a safety device located at each mill, and
49
CHAPTER 4- MACHINERY DANGER ZONE AND POINTS OF OPERATION
when a visible signal such as a lamp is the charging floor or platform, a standard railing
operated by the motor circuit opening switch or enclosure shall be provided which will prevent
is open, and the safety device has been the operator from falling into the pan.
tripped, then after mill line has been stopped
by actuating one safety trip for the first test Section 13.0 Cotton and Seed Cotton
and before the mills are restarted, the Processing Machines
remaining safety devices may be tripped
and the lamp signals used as an indication 13.1 Saws:
of the proper functioning of the tripping
devices and motor switch. After a particular a. All gin stands used in processing field cotton
stopping device has been used to stop the or seed shall be provided with a positive
motor driving a group of mills for a test, the guard which shall be designed to prevent
same device may not be used for the same contact with the gin saws while in motion.
purpose until all the other devices have The saw blades in the roll box shall be
been similarly used. considered guarded by location if they do
not extend the ginning ribs into the roll box
b. Each stopping device shall be tested for when breast is in the out position.
braking distance once a week by a
competent person, and a record of such test b. Moving saws on lint cleaners having doors
shall be made and kept on file for at least giving access to the saws shall be guarded
one year. Such records shall be available to by interlock barred barriers, or equivalent.
the division or its employees.
13.2 Gin Stand, Main Drive and Miscellaneous
c. The employer shall cause all defects or Drives.
substandard condition revealed by the test
to be corrected. a. Such drives shall be completely enclosed or
guarded by means of standard railings or
Section 12.0 Stone, Clay and Glass equivalent protection provided. When
Working Machines guarded by standard railing, where the
driver approaches the railing by less than
12.1 Pug Mills (Class A). Pug mills shall be guarded 380 mm, shield guards shall be installed on
by: the railing extending at least 380 mm
beyond the impairment on either side.
a. A substantial grating with openings no
greater than 100 mm, said grating to b. V-belt drives within standard railing
completely cover the opening, or enclosures shall have the pulleys guarded.
The open end of the pulleys shall be no less
b. A cover projecting 100 mm on all sides that 100 mm from the periphery of the
which may be raised not more than 200 mm pulleys.
above the machine or floor, so as to permit
loading into machine on all sides without c. Chains and sprockets within 2 130 mm of
screening same through grating, or the floor or working level shall be guarded.
Chains and sprockets more than 2 130mm
c. A hoper completely encircling the opening from the floor or working level need not be
through which the machine is fed and guarded provided the bearings are packed
extending 400 mm or more above the blade. and accessible extension lubrication fittings
In no case shall the top of the hopper be are used.
less than 900 mm from any floor or working
level used by the pug mill operators or 13.3 Elevated Platforms and Transmission
attendants. Enclosures.
12.2 Wet and Dry Pans, Mullers, Chasers and b. Where belts, pulleys, chains, sprockets,
Similar Mixing and Grinding Mills (Class A). gears or shifting are within 380 mm
When the top of pan is less than 914 mm above horizontally or less than 2 130 mm above
50
CHAPTER 4- MACHINERY DANGER ZONE AND POINTS OF OPERATION
the plafform shield guards as provided in below the floor level may be guarded by
Section 4.13.2 shall be used in addition to standard railing guards having two boards of
standard railing guards. midrail height or shall be covered by
substantial covers or gratings.
13.4 Power Drives
e. All belt conveyors head pulleys, tail pulleys,
a. Drives between gin stands shall be guarded. single tension pulleys and dip take-up
Where individual pulley guards are used, the pulleys shall be so guarded that the entire
guards must extend 100 mm beyond the sides of the pulleys are covered. The guard
periphery of the pulleys. shall extend in the direction of travel of the
belt to such a distance that a person cannot
b. Drives which are accessible above the reach behind it and be caught in the nip
shield guard shall be individually guarded. point between the belt and the pulley.
13.5 Warning Device. A warning device which will f. Portable inclined conveyors shall have head
sound an audible signal before machinery is and tail pulleys or sprockets and other
started shall be installed in all gins. Such signal power transmission equipment guarded
shall be intense enough to be heard above the accordingly.
general noise level.
g. Where necessary to pass over exposed
13.6 Baler. An automatic interlock shall be installed chain, belt, bucket, screw, or roller
on all balers so that the upper gates cannot be conveyors, such crossovers shall be bridged
opened while the tramper is operating and the or catwalked properly equipped with
tramper cannot operate while the gates are standard railings and toe boards and shall
open. have a safe means of access either fixed
ladder, ramp or stairway.
13.7 Burr Machines. Top panels of burr extractors
must be hinged and equipped with a sturdy h. Conveyors passing over areas that are
positive latch. occupied or used by employees shall be so
guarded as to prevent the materials handled
13.8 Conveyors from falling and causing injury to employees.
a. All accessible screw conveyors shall be i. Where workmen pass under the return
guarded by substantial covers or gratings or strands of chain conveyors a shallow
with an inverted horizontally slotted guard of through or other effective means of sufficient
the trough type, which will prevent personnel strength to carry the weight of the broken
from coming into contact with the screw. chain shall be provided.
Such guards may consist of horizontal bars Section 14.0 Other Industrial Machinery in
spaced to allow material to be fed into the
conveyor and supported by arches which
Manufacturing Installations.
shall be not more than 2 440 mm apart.
Screw conveyors under gin stands shall be
14.1 Machine Guards for Operator’s Protection.
considered guarded by location.
Applicable machine guards of the types describe
b. shall be provided at points of operation and
All accessible seed cotton conveyors shall
danger zones to protect the operator from
be of the belt type.
hazards of accidental contact.
c. Wherever practical in existing installations
screw conveyors shall be replaced with belt a. Coupling Guards — pairs or groups of
conveyors. guards which may mesh together to form
an enclosure around the point of operation
d. during machine operation.
Screw conveyors 2 100 mm or less above
floor or other working level shall be
b. Chain Guards fixed-mounted or movable
completely covered with substantial lids. —
Screw conveyors which are 600 mm or less hood guards covering the length of run of -
51
CHAPTER 4- MACHINERY DANGER ZONE AND POINTS OF OPERATION
c. Belt Guards — fixed-mounted or movable 15.1 Electrical Safety Hazards shall be painted in
guards or enclosures covering the length of red-orange color.
run of belts.
15.2 Outdoor installations shall be drip proof
d. Distance Rail Guards fixed-mounted or
—
enclosure for weather protection.
movable guards designed to prevent
personnel from moving into danger zones. 15.3 Motor terminal box covers shall be
weatherproof.
e. Hood Guards — fixed-mounted or
retractable enclosures covering the vicinity 15.4 In wet workplaces, water splash motor enclosure
of the point of operation or danger zone. shall be provided.
explosion resistant enclosures covering the last line of defense against hazards in the
vicinity of the point of operation of danger work environment. The engineer shall specify
zone and designed to contain energy and require the use of PPE to protect personnel
bursts and flying materials. from known or possible hazards in the
workplace.
i. Railings and Screen Doors Retractable
—
type railings or access doors resistant to 16.2 Employers’ shall protect their employees by
flying materials and encloses the vicinity of providing appropriate and approved protective
the point of operation or danger zone, and tools, devices, equipment and appliances such
is designed to isolate the same without as, but not limited to the following:
impairing ocular inspection.
a. Head Guards
14.2 Machine guards provided for mechanical power b. Face Shields
transmission from the prime mover to the point c. Eye Goggles
of operation shall be made of enclosure that d. Ear Muffs
permits visual inspection at a distance while e. Nose Aspirator
machine is running. f. Hand Gloves
g. Arm Sleeves Shield
14.3 For easy identification of safety hazards, all
h. Body Apron Shield
machine guards shall be painted in yellow color,
i. Leg Sleeve Shield
and restricted floor area shall be painted with
yellow strip line in walk aisles around the
j. Foot Safety Shoes
k. Foot Rubber Boots
machinery.
163 Radiation hazards in workplaces shall be
14.4 For automatic start-stop machines, a warning identified and appropriate warning signs shall be
sign, tag or nameplate shall be displayed in posted.
strategic location in the workspace.
16.4 Eye hazard from welding arc electrical flashes in
Section 15.0 Protection for Electrical welding shop shall be shielded by wood panel
Machinery in Commercial & Industrial barrier as protection for observers and other
Installations personnel in the work area.
52
CHAPTER 5- CRANES AND OTHER HOISTING EQUIPMENT
Chapter 5
Section 1.0 Scope Bumper. A device which stops the moving part at the
limit of travel of a trolley, bridges, or crane operating
The provisions in this Chapter apply to overhead on rails, and prevents further motion beyond that point.
traveling or bridge cranes, storage bridges, gantry
cranes, portal cranes, jib cranes, hammerhead cranes, Cab. An enclosure for housing the operator and the
pintle cranes, wall cranes, tower cranes, and any hoisting mechanism, power plant, and equipment
.
53
CHAPTER 5— CRANES AND OTHER HOISTING EQUIPMENT
swinging arms carrying a trolley hoist or other structure, adapted to hoist and swing load over
hoisting mechanism. high obstructions and mounted upon a fixed or
mobile tower-like gantry. The revolving crane may
7. Locomotive Crane. A boom type mobile crane be supported on the lower tower by a revolving
consisting of a self-propelled car operating on a mast or by a turntable.
railroad track, upon which is mounted a rotating
18. Tractor Crane. (caterpillar crane) (see crawler
body supporting the power operated mechanism
together with a boom capable of being raised or crane).
lowered at its head (outer end) from which is led to
the wire rope or chain connected to the hoisting 19. Wall Crane. A crane having jib with or without a
mechanism for raising or lowering a load. trolley and supported from a side wall or line of
columns of a building so as to swing through an
8. Motor-Tractor Crane. (see crawler crane). arc.
9. Motor Truck Crane. A boom type mobile crane Crane Runway the structure upon which a crane
—
54
CHAPTER 5- CRANES AND OTHER HOISTING EQUIPMENT
5. Overhead Electrical Hoist. A motor-driven hoist Section 3.0 General Requirements For
having one or more drums or sheaves for rope or
chain, and supported overhead. It may be fixed or
Cranes
traveling
3.1 Access to Cage, Cab or Machine House
6. Simple Drum Hoist. A hoist with one or more Required:
drums controlled by manually operated clutches,
a. Access to the cage, or machine house shall
brakes or ratchet and pawl on drum and control
be afforded by a conveniently placed
levers, which is operated by hand or power.
stationary ladder, stairs, or platform
Note: This type of hoist is known to the trade as a requiring a step-over. No gap exceeding 300
contractor’s hoist and is usually a portable unit mm (and in no case exceed 815 mm) shall
be so located that a person approaching or
7. Double Drum Hoist. A simple drum hoist having leaving the crane shall not be exposed to
dangerous shear hazards.
two independent hoisting drums.
8. b. For the bridge and gantry cranes, there shall
Single Drum Hoist. A simple drum hoist having
be a ladder, stairs or other safe means
only one hoisting drum.
provided for convenient access to the bridge
walkway. Where the cage is attached to and
9. Single Fixed Drum Hoist. A single drum hoist
with the drum geared or fixed directly to the power below bridge girders, no portion of the cage
or cage platform shall be in the protected
unit (including the speed reducing apparatus)
instead of by means of friction clutches. area between the girders unless there are
adequate bridge stops or bumpers to
10. Triple Drum Hoist. A simple drum hoist having prevent the trolley from passing over said
three independent hoisting drums. projected area opposite the cage.
11. Trolley Suspension Hoist. A hoist whose upper c. When necessary to go out on booms or
suspension member is a trolley, for the purpose of bridges to oil the blocks or other parts of the
running the hoist below a suitable runway, it may machinery, each boom or bridge shall be
equipped with a suitable oiler’s walkway or
be either floor or cage-operated.
platform with grab irons giving access to the
Jib: (1) A horizontal arm, for supporting a trolley or fall outrig blocks and machinery. Permanent
block, which does not change its inclination with the elevated platforms attached to the building
horizontal; or (2) An extension added to the head of a at the end of the bridge crane runways and
at the same level of the bridge will be
boom for increasing the reach.
acceptable in lieu of the oiler’s platform on
Radius (of a Crane or Derrick). The horizontal the bridge. Single girder or monorail bridges
distance from the center of rotation of a tower, with underhung trolleys and hoists are
hammerhead portal or pillar crane, or derrick to the exempt from this requirement provided the
center of the hook or load. hoists and trolleys are serviced or repaired
from a safe portable ladder or other safe
Swinging or Slewing. The act of moving a boom temporary means. Booms which can be
through a horizontal arc. and are safely lowered to a safe location for
such servicing operation will be exempt from
Trolley. A truck or carriage on which the hoisting this requirement.
mechanism is mounted and which travels on an
overhead beam, or track. It may be either “over d. Where practicable every overhead traveling
running” (riding above its wheels); or “under-running” crane walkway shall have a headroom of at
or suspended under the beam, bridge, or track. least 1 950 mm. However, when such
headroom is not practicable, the crane
Truck (of an Overhead, Gantry, or Locomotive walkway shall have at least 1 500 mm
Crane). The framework and wheels operating on the clearance or it shall be omitted from a crane
runway or rails and supporting the bridge, trolley, or and a permanent elevated platform attached
body of the crane. to the building at the end of the crane
runway be provided.
55
CHAPTER 5- CRANES AND OTHER HOISTING EQUIPMENT
3.2 Outdoor Cages, Cabs, or Machine Houses. voluntary effort to move it from the “off’
The cages, cabs, or machine houses on cranes position to the “on’ position.
used in inclement weather shall be enclosed to
protect the operator. d. All electrically operated cranes shall have
their controller plainly marked to indicate its
3.3 Warning Devices: functions and which equipment it controls.
a. A gong or other effective warning signal e. The controller operating handles shall be
shall be mounted on each cage or cab located within convenient reach of the
controlled crane equipped with a power operator.
traveling mechanism. Cage or cab
controlled cranes operating over areas f. As far as is practicable, the movement of
congested with employees may be required each controller handle shall be in the same
to be equipped with automatic warning general direction as the resultant
devices which can be sounded continuously movements of the load.
while the crane is in motion.
g. The controls for the bridge and trolley shall
b. Any cage or cab controlled crane whose be so located that the operator can readily
warning device has become inoperative see the direction of travel while operating
shall not be operated until the warning the controls.
device is repaired or replaced. Temporary
crane operation will be permitted provided h. All electric cranes of the same type
there is an available flagman whose sole operating in a given plant shall e so wired
duty is to warn those in the path of the crane that like motion of controller handles will
or its load. produce like effect in similar controlled
mechanisms.
3.4 Fire Extinguisher. A carbon-tetrachloride,
carbon dioxide, or other non-conducting 3.6 Hoist Limit Switches. The hoisting motion of all
medium, portable fire extinguisher shall be kept electric overhead traveling cranes shall be
in the cage, cab or machine house of each provided with a suitable and effective enclosed
electric or internal combustion engine crane. type limit switch so placed and arranged as to
disconnect the hoist motor and apply the brake
Note: Careshould be taken when using carbon in time to stop the motor before the hook passes
tetrachioride in an enclosed space and such the highest point of safe travel.
space should not be re-occupied until thoroughly
ventilated. 3.7 Brakes:
56
CHAPTER 5- CRANES AND OTHER HOISTING EQUIPMENT
sufficient torque to sustain one and one-half rated load at maximum radius can be held
(1 1/2) times the rated load. suspended without the help of the boom
hoist brake and with crane mechanism
3.8 Foot Brake Pedal. Foot brake pedals shall be stationary.
so roughened or covered with high friction
material that the operator’s foot will not easily 3.12 Runway Bumpers. At the limits of travel of the
slip off. bridge or gantry structures, bumpers shall be
provided which will prevent bridge or gantry
3.9 Locking Device. A locking device capable of structures from leaving the ends of the rails. If
withstanding 50 percent more than the the bumpers engage the tread of the wheel they
maximum rated load shall be provided on each shall be of a height at least equal to the radius of
hand or foot operated hoisting motion brake the wheel.
unless a paw is provided on the drum.
3.13 Trolley Bumpers:
3.10 Brakes for Bridge and Swinging Motion:
a. Bumpers shall be provided at each end of
a. On cage-operated cranes with the cage the trolley travel to prevent trolleys leaving
mounted directly on the bridge grinders, a the rails. If the bumpers engage the tread of
foot brake to properly retard and stop the the wheel they shall be of a height at least
motion of the bridge shall be installed unless equal to the radius of the wheel.
the bridge stops automatically when the
power is cut off. This does not apply to b. If there is more than one trolley on the same
underslung cab monorail cranes. bridge girders, buffers or other cushioning
shall be placed between the trolleys.
b. Brakes for retarding the motion of the bridge
shall be capable of retarding it at the rate of 3.14 Bridge or Gantry Buffers. If there is more than
305 mm/mm., while full load is being carried. one crane on the same runway, buffers or other
cushioning devices shall be placed between the
c. The swinging or slowing mechanism on crane at both ends of the bridge or gantry.
boom-type cranes shall be provided with a
brake or lock having adequate holding 3.15 Truck Fenders:
power in either direction. The lever
operating this brake or lock shall have a a. Bridge truck wheels, except on under hung
device by which it can be secured in the cranes shall be equipped with fenders which
hold or locked position. extend below the top of the rail and project
in front of the truck wheels.
3.11 Booming Mechanism. All boom-type cranes
equipped with a mechanism for raising and b. Gantry, tower, hammerhead, or portal crane
lowering the boom shall comply with the truck wheels shall be equipped with wheel
following requirements: guards, or be otherwise similarly guarded at
both ends of each truck to prevent a person
a. Brake. Worm geared boom hoist being crushed beneath the wheels. The
mechanism the worm angle of which is such clearance between the guard and the rail
as to permit the loaded boom to lower shall shall be such as will afford maximum
be equipped with a brake to hold the loaded protection against crushing injuries.
boom in any position. Wherever practicable 12.70 mm clearance
shall be maintained.
b. Ratchet and Pawl. A ratchet and pawl, shall
be provided on the mechanism for raising 3.16 Capacity Marking and Load Indication:
and lowering the boom, unless a self-locking
worm and gear is part of the mechanism. a. The maximum rated load of all cranes shall
There shall be no intervening clutch be plainly marked on each side of the crane,
between any boom hoist drum and its and if the crane has more than one hoisting
reduction gear train. unit, each hoist shall have marked on it or its
load block its rated capacity; and this should
Note: A worm and gear shall be accepted be clearly legible from the ground or floor.
as self-locking under this code when full
57
CHAPTER 5— CRANES AND OTHER HOISTING EQUIPMENT
b. Each variable radius boom-type crane shall Section 4.0 Boom Type Mobile Cranes
be equipped with a safe load diagram or
table which will give a clear indication of the 4.1 Operating Levers:
permissible loads at the various radii.
a. Lever operated controllers shall be provided
c. If change-speed gear is used on the lifting with a mechanical device which will hold the
motion, the rated load for each speed shall handle in the “off” position requiring
be similarly indicated. voluntary effort to remove it from “off’ to the
“on” position.
3.17 Runway Repair. No repairs on traveling crane
runways or within such proximity to same as to b. The operating levers shall be located within
constitute a hazard to workmen shall be made convenient reach of the operator.
unless a wheel stop of a height at least equal to
the radius of the wheel is secured to each rail 4.2 Boom Stops. Booms shall have a device
and a warning sign is placed on each rail a designed and constructed to prevent the boom
reasonable distance from the worker, or properly from falling over backwards.
shielded rail-road torpedoes or watchman are
used to warn workers of the approach of the 4.3 Capacity Marking. Substantial plates of metal
crane. or other durable material shall be attached at a
conspicuous place on the crane have cast or
3.18 Crane Runways: stamped thereon the rated load at the maximum
and minimum radii. Suitable signs shall also
a. Runway columns shall be securely provide the rated load for at least two other
anchored to foundation. points on the boom, and which shall be visible
on the boom along both parallel and transverse
b. The structure shall be free from excessive tot the line of travel. The indicators shall be
vibration under operating conditions. given for loads both with and without outriggers
when such outriggers are provided.
c. Runway girders shall be level and parallel
within commonly accepted engineering 4.4 Access to Cage, Cab, Machine and Boom
tolerances. Blocks:
58
CHAPTER 5- CRANES AND OTHER HOISTING EQUIPMENT
mesh or similar guard to prevent injury from separate drums permanently keyed to the
flying pieces of glass. same shaft.
4.7 Couplers: 4.12 Warning Device. An adequate whistle, gong,
bell or other warning device shall be provided for
a. If locomotive cranes are equipped with all boom type mobile cranes.
couplers these must be extended to clear
the revolving tank end of the crane. 4.13 Wheel Guards. Locomotive cranes shall be
provided with either a running board which shall
b. Automatic couplers shall be provided on extend full width of the truck bed. And with a
cranes that switch or couple to cars so grab iron extending across and near outer end
equipped. of the truck bed, or with a pilot or fender which
will prevent a man being crushed beneath the
4.8 Lubricator Glass. The steam lubricator glasses truck wheels.
on all locomotive cranes and steam shovels
shall be effectively guarded to prevent injury to 4.14 Truck Wedges or Jacks. Where loads greater
flying glass unless the lubricator is of the bull’s than the capacity of the springs are to be lifted,
eye type or sight feed glass. locomotive cranes shall be provided with
suitable removable wedges or jacks for
4.9 Brake or Locking Device. Boom type mobile transmitting loads from the crane body directly
cranes shall be equipped with an effective brake to the wheels without permitting the truck
or swing lock for the swinging mechanism. The springs to function, when handling heavy loads.
braking mechanism shall be equipped with a These wedges should be removed, or jacks
device to secure it in holding position. released in a positive manner, for traveling.
4.10 Booming Mechanism: 4.15 Fire Extinguisher. A carbon tetra-chloride,
carbon dioxide, ansul, or other non-conductive
a. Every worm guarded booming mechanism medium hand fire extinguisher shall be kept in or
whose worm angle is such as to permit the just outside the cage cab or machine house of
loaded boom to lower shall be equipped with each electric, internal combustion engine or
a brake to hold the loaded boom in any steam driven mobile boom type crane.
position.
4.16 Lighting. Boom type mobile cranes which
b. A ratchet and pawl shall be provided on the operate at night shall have loads hooks and
mechanism for raising and lowering the working areas adequately illuminated. Such
boom, unless a self-locking worm and gear lighting can be accomplished either by outside
is part of the mechanism or unless the lighting placed on the booms or cabs. Boom
booming mechanism is of such design as to heads and hooks should be painted with high
prevent the free fall of the bottom upon visibly yellow or other contrasting colors.
release of the boom hoist brake.
Section 5.0 Hoists
Note: A worm and gear will be accepted as
self-locking under this code when full rated 5.1 Limit Switches. Each overhead electric hoist
load at maximum radius can be held motor shall be equipped with an effective
suspended without the help of the boom enclosed type limit switch so placed and
hoist brake and with crane mechanism arranged as to disconnect the motor and apply
stationary. the brake in time to stop the motor before the
hook passes the highest point of safe travel.
4.11 Rigging of the Boom Hoisting Line:
5.2 Brakes:
a. No line shall be wound on any free running
drum of a boom type mobile crane. a. Each electric hoist motor shall be provided
with an electrically or mechanically operated
b. All boom type mobile cranes shall have one brake so arranged that the brake will be
end of the boom line dead ended except applied when the power is cut off from the
where ends of the boom line are on
hoists. This brake shall have sufficient
59
CHAPTER 5- CRANES AND OTHER HOISTING EQUIPMENT
holding torque to sustain not less than one positioned for trolley travel from stationary
and one-half times the rated load. rails to movable bridges or vice-versa.
b. Each independent hoisting unit shall be 5.6 Control Equipment. Operating controls shall
equipped with two braking means except be plainly marked to indicate the direction of
worm geared hoists, the angle of whose travel.
worm is such as to prevent the load from
lowering and simple drum hoists which need 5.7 Warning Device. Each cage controlled hoist
have but one braking means. One brake will shall be equipped with an effective warning
be so covered by: device.
5.4 Capacity Marking. Each hoist designed to lift b. Guyed derricks should have at least six
its load vertically shall have its rated load legibly guys (only under special consideration of
marked on the hoist or load block or some circumstances shall guyed derricks be
equally visible space. allowed to have less than four guys).
60
CHAPTER 5- CRANES AND OTHER HOISTING EQUIPMENT
a. Every derrick shall have plainly marked on it b. Eye splices shall be made in a manner to
the length of the boom, the rated load and develop maximum splice efficiencies as set
the corresponding radius. forth in the manufacturer’s tables.
b. Derricks of variable radius shall have c. Where wire rope clip attachments are used
substantial plated metal or other durable they shall be made with U-bolts on the dead
material conspicuously posted on which or short end of the rope and saddle on the
shall be given the rated load of at least four live end.
different radii of operation, including the
maximum and minimum radius. d. No ‘Contractor’s Standby” (knot and clip)
attachment shall be used as an end
6.3 Hoisting Ropes. Wire ropes running from connection on any permanent hoisting sling
hoisting machine to derrick shall be guarded if or rope.
within 2 135 mm of floor or platform.
e. The maximum number of clips for end
6.4 Access to Sheaves, Bearings and Blocks. If attachment shall be not less than those
necessary to go out on derrick booms to service indicated in the manufacturer’s table, but in
sheaves, bearing or blocks, said boom must be no case shall it be less than three for any
equipped with substantial oiler’s catwalk and permanent installation. The clips shall be
necessary grab irons to give access to the spaced at a distance equal to at least six
equipment to be serviced. times the diameter of the rope.
Section 7.0 Auxiliary Hoisting Equipment f. All clip or clamp bolts shall be kept tight.
7.1 Hoisting Chains and Ropes: g. Where swaged or compressed fittings are
used they shall be applied in a manner
a. All chains, wire ropes, and fiber ropes used specified by the manufacturer.
for hoisting purposes shall be of sufficient
strength to safely lift or otherwise handle the 7.4 Chain Splices:
loads. The maximum allowable working
loads shall be based on manufacturer’s a. No hoist chain shall be spliced by any
tables. makeshift means.
b. Every hoist chain, wire rope and fiber rope b. Knots shall not be tied in the chain to
in hoisting drums shall be of sufficient length shorten it.
that the hoist hook shall at least reach the
floor, ground, or lowest working level. c. Lap link, cold shuts or patent repair links
Where this is not practicable lower-limit shall not be used for hoist chain or slings
switches may be used to restrict the unless such device will develop greater
downward limit of travel. strength than the chain.
Exemption: Chain hoists employing pocket 7.5 Hoist of Sling Hooks, Rings, and Chain
sheaves instead of drums. Links, Defective. The use of deformed or
defective hooks, rings, or chain links shall be
7.2 Hooks, Slings and Fittings. All hooks, slings discontinued forthwith. Deformed hooks or rings
and other fittings shall be of correct size for the shall be reshaped only by the manufacturer of
work to be done and shall have strength the hooks or rings under proper metallurgical
sufficient to safely sustain the loads imposed control and proof tests unless the employer is
upon them. equivalently competent to make these repairs
and tests.
7.3 End Attachment:
7.6 Sheave Nip-Points. All nip or contact points
a. Where socketing is done it shall be done between ropes and sheaves which are
with zinc (spelter) or in a manner specified permanently located within 2 135 mm from the
by the manufacturer of the wire rope. floor or working platform shall be guarded.
61
CHAPTER 5- CRANES AND OTHER HOISTING EQUIPMENT
Section 8.0 Operating Rules 8.6 Signalling. Only qualified employees shall give
signals. No one would give signal except
8.1 Size of Load. A crane, derrick, or hoist shall not employees who are specifically designated and
be loaded beyond the rated capacity or safe authorized to do so by the employer. Crane
working load whichever is smaller. operators shall not accept signals except from
those specifically designated and authorized to
8.2 Attaching the Load: give same.
b. Cranes, hoists, or derricks shall not be left 5. Raise Boom; Arm extended, fingers
unattended while load is suspended over closed, thumb• pointing upward
water, is barricaded or is blocked up or move hand up and down.
otherwise supported from below during
repairs of emergency. 6. Lower Boom. Same as (e), but with
thumb pointing down.
8.5 Limit Switch:
7. Swing Boom. Arm extended, point
a. Before an electric crane is operated for the with finger in direction of motion.
first time during any shift, the operator shall
test the operation of the limit switch over a 8. Bridge Travel. Arm extended, hand
cleared area under no load and shall report open and slightly raised wave
any defect to his employer who shall have forearm in direction of travel, while
the defect corrected before the crane is facing in that direction.
permitted to operate.
9. Rock or Trolley Travel. Palm
b. The limit switch shall never be used as an upward, fingers closed, thumb
operation control unless designed for such pointing in direction of motion, jerk
use. Where such limit switches are used as and horizontally.
operating controls there shall be a second
limit switch located behind the control limit
switch.
62
CHAPTER 5- CRANES AND OTHER HOISTING EQUIPMENT
63
CHAPTER 6- ELEVATORS, DUMBWAITERS, ESCALATORS AND MOVING WALKS
Chapter 6
the car which may visually or audibly indicate or call resting on and attached to the car platform.
attention to such information as the floor level, full or
overload conditions, manual or automatic operation,
Car Frame (Sling) The supporting frame to which
—
or counterweight beyond its normal limit of travel by A car frame to which the
Car Frame, Oversiung —
stop a descending or falling car or counterweight Car Frame, Sub-Post A car frame all of whose
—
beyond its allowable lower limit of travel by absorbing members are located below the car frame.
the energy or impact of descent.
Car Frame, Underslung A car frame to which the
—
64
CHAPTER 6- ELEVATORS, DUMBWAITERS, ESCALATORS AND MOVING WALKS
top of the car where no cross-head, is provided, and Door or Gate, Self-Closing A manually opened
—
the nearest part of the overhead structure or any other hoistway door or gate that automatically closes when
obstruction when the car floor is level with the top released.
terminal landing.
Dumbwaiter —A hoisting and lowering mechanism
Clearance, Top Counterweight The shortest
— design to materials and other loads such as food,
vertical distance between any part of the laundry, etc., equipped with a car, which moves in
counterweight structure and the nearest part of the fixed guides and serves two or more fixed landings
overhead structure or any other obstruction when the through a hoistway. This equipment shall be designed
floor is level with the bottom terminal landing. to carry small materials in a car, or partitioned or
shelved enclosure measuring no more than 0.86 m 2 of
Compensating-Rope Sheave Switch A device
— net platform area; with a height no more than 1.2
which automatically causes the electric power to be meters and a maximum rated capacity no greater than
removed from the elevator driving-machine motor and 225 kg.
brake when the compensating sheave approaches its
upper or lower limit of travel. Dumbwaiter, Under Counter A dumbwaiter which
—
retardation of the moving number. than a dumbwaiter or freight elevator which is design
to carry passenger or authorized personnel, in a
Control, Single-Speed Alternating Current A — protected enclosure (elevator car) which moves along
control for a driving machine induction motor which is fixed guides and serves two or more fixed landings on
arranged to run at a single speed. a hoistway.
65
CHAPTER 6- ELEVATORS, DUMBWAITERS, ESCALATORS AND MOVING WALKS
elevator which is limited in size, capacity, rise, and Hoistway Door I Gate Locking Device — A device
speed, and is installed in a private residence or in a which secures a hoistway door or gate in the closed
multiple dwelling as a means of access to a private position and prevents it from being upended from the
residence. landing side excerpt under certain specified
conditions.
Emergency Stop Switch A device located in the car
—
which when manually operated, causes the electric Hoistway-Unit System A series of hoistway door
—
power to be removed from the driving machine motor interlocks, hoistway door electric contacts or hoistway
and brake of an electric elevator or from the door combination mechanical locks and electric
electrically operated valves and/or motor of a hydraulic contacts, or a combination thereof, the function of
elevator. which is to prevent operation of the driving machine by
the normal operating device unless all hoistway doors
Entrance Locked Out of Service An entrance in
— are in the closed position and, are locked in the closed
which the hoistway door is mechanically locked by position.
means other than the interlock to prevent the door
being opened from the car side without keys or special Hoistway Door Combination Mechanical Lock and
equipment. Electric Contact A combination mechanical and
—
66
CHAPTER 6- ELEVATORS, DUMBWAITERS, ESCALATORS AND MOVING WALKS
so required by this code, are locked in the closed (c) Traction Machine A direct driven in which the
—
hall stop-or-signal calls have been registered and are without intermediate gearing, which has the
unanswered. traction sheave and the brake drum mounted
directly on the motor shaft.
Landing, Elevator or Material Lift That portion of a
—
floor balcony or platform used to receive and (e) Winding-Drum Machine A geared-drive
—
mm below an elevator or material lift landing to a point (f) Worm-Geared Machine A geared-drive
—
457 mm above landing. machine in which the energy from other motor is
transmitted to the driving sheave or drum through
Leveling — Controlled car movement toward the worm gearing.
landing, within the leveling zone, by means of a
leveling device, which vertically aligns the car-platform (g) Indirect-Drive Machine —An electric driving
sill relative to the hoistway landing sill to attain a machine, the motor of which is connected
predetermined accuracy. indirectly to the driving sheave, drum or shaft by
means of a belt or chain through intermediate
Leveling Device, One-Way Automatic — A device gears.
which corrects the car level only in case of under-run
of the car, but will not maintain the level during loading Material Lift — A hoisting and lowering mechanism
and unloading. normally classified as an elevator has been modified
to adapt it for the automatic transfer device.
Leveling Device, Two-Way Automatic Maintaining
— A device which corrects the car level on both under Moving Walk — A power-driven device made of a
run and over-run, and maintains the level during continuous belt treadway or pallets used to convey
loading and unoading. passengers and/or materials on a horizontal plane
from one point to another; the types of which as
Leveling Zone The limited distance above or below
— follows:
an elevation or material lift landing with which the
leveling device is permitted to cause movement of the (a) Moving Walk, Belt Type A moving walk with a
—
energy necessary to raise or lower an elevator or with a series of connected and power-driven
dumbwaiter. pallets to which a continuous treadway is
fastened.
Machine Drive, Electric —One where the energy is
applied by an electric motor. It includes the motor, (c) Moving Walk, Pallet Type A moving walk with a
—
brake, and the driving sheave or drum together with its series of connected and power-driven pallets
connecting gearing, belt or chain, if any, and can be which together constitutes a treadway.
classified as follows:
Non-Stop Switch, Elevator A switch, which when
—
(a) Direct-Drive Machine — An electric driving operated will prevent the elevator from marking
machine, the motor which is directly connected registered landing stops.
mechanically to the driving sheave, drum, or shaft
without the use of the belts or chains, either with Operator, Automatic Operation wherein the starting
—
67
CHAPTER 6- ELEVATORS, DUMBWAITERS, ESCALATORS AND MOVING WALKS
lever or other manual device used to actuate the devices by means of which the starter may control the
control. manner in which an elevator or group of elevators
function.
Overhead Structure All the structural members
—
platforms, etc. supporting the elevator machinery, Static Switching —Switching of circuits by means of
sheaves and equipment at the top of the hoistway. solid state devices.
mechanical device the function of which is permit the other device, located at an elevator landing which
opening from the landing side of the hoistway door at when actuated, causes the elevator to stop at that
any landing when the car is within the landing zone of floor.
that landing. The device may also be used to close
the door. Terminal Speed Limiting Device, Emergency — A
device which automatically reduces the speed as a car
Rope Equalizer, Suspension A device installed on
— approaches a terminal landing, independently of the
an elevator car or counterweight to equalize functioning of the operating device, and the normal-
automatically the tensions in the suspension wire terminal stopping device, if the latter fail to slow down
ropes. the car as intended.
attached to the c,ar or counterweight or to the which automatically causes the power to be removed
overhead dead-end rope-hitch support which will from an electric elevator driving machine motor and
function automatically to support the car or brake at a pre-determined distance from the terminal
counterweight in case the regular wire-rope fastening landing, and independently of the functioning of the
falls at the point of connection to the car or operating device and the normal terminal stopping
counterweight or at the overhead dead-end hitch. devices does not slow down the car as intended.
The distance the elevator car can run above its top
Signal Device, Elevator Car Flush One providing a
— terminal landing before the plunger strikes the
signal light in the car, which is illuminated when the mechanical stop.
car approaches the landings at which a landing signal
registering device has been actuated. Transom A panel or panels used to close a
—
causes the electric power to be removed from the Travelling Cable —A cable made up of electric
elevator driving machine motor and brake when the conductors, which provides electrical connection
suspension ropes of a winding-drum machine become between an elevator, dumbwaiter, or material lift car
slack. and fixed outlet in the hoistway or machine room.
68
CHAPTER 6- ELEVATORS, DUMBWAITERS, ESCALATORS AND MOVING WALKS
69
CHAPTER 6- ELEVATORS, DUMBWAITERS, ESCALATORS AND MOVING WALKS
2. Overhead sheaves, governors, and 3.5 Hoistway for elevators outside building shall be
other equipment where the elevator substantially enclosed to a height of at least
machine is located below or at the 3 000 mm provided that the enclosure shall be
side of the hoistway. continuous to the top of any side on which there
is access to the cage.
b. Location of Floor. The floor shall be
located: 3.6 The enclosure shall either be a continuous wall
or substantial grill work, metal bars, or wood
1. Above or level with the tope of the slats.
machine beams where the machine
is located over the hoistway; 3.7 Openings fixed enclosures shall not exceed 50
mm in their lesser dimensions, at all places
2. Below the overhead sheaves where where moving cars, counter-weights, or sliding
the machine is not located over the doors present hazard they shall not exceed 10
hoistway. mm in their lesser dimensions.
c. Strength of Floor. The floor shall be 3.8 Hoistway enclosures and hoistway doors and
capable of sustaining a concentrated load of door assemblies shall be of fire-resistive
136 kg on any 2 580 mm area and in construction of not less than 1-hour fire
addition where it constitutes the floor of the resistance.
main or secondary level machinery space, it
shall be designed for a live load of not less 3.9 Where four or more elevators serve or the same
than 611 kg/rn in all open areas. A sign portion of a building, they shall be located in not
stating the maximum allowable load of less than two (2) hoistway and in no case shall
which the floor is designed shall be more than four (4) elevators be located in any
permanently displayed in all main and one hoistway.
secondary machine-room spaces. The sign
shall be of metal with black letters and 3.10 Window and Skylights:
figures at least 100 mm high on a white
background. a. Window and Skylight Frames and Sash.
Windows in the walls of hoistway enclosures
d. Construction of Floors. Floors may be of are prohibited. Frames and sashes of
concrete, or may be of metal construction windows in machine rooms and skylights
with or without perforations. Metal floors shall be of metal.
shall conform to the following:
1. Skylights Guards. A guard
1. If of bar-type grating, the openings securely anchored to the supporting
between bars shall reject a ball 20 structure, consisting of a wire mesh
mm in diameter. screen of at least 2.325 mm
diameter steel wire with openings
2. If of perforated sheet metal or of which will reject a ball 25 mm in
fabricated open work construction, diameter, or an expanded metal
the openings shall reject a ball 25 screen of equivalent strength and
mm in diameter. open area, shall be installed above
every elevator skylight. A similar
screen of at least 1.205 mm
70
CHAPTER 6- ELEVATORS, DUMBWAITERS, ESCALATORS AND MOVING WALKS
diameter steel wire, or of expanded from the landing except with special emergency
metal of equivalent strength and key.
open area, shall be installed below
every elevator skylight. 4.5 Landing opening in passenger-elevator hoistway
enclosure shall be protected preferably by
Section 4.0 Machine Rooms and sliding doors, combination sliding and swing
doors, or swinging doors.
Machinery Spaces
4.6 Access to Machine Rooms and Machinery
4.1 Enclosure Required:
Spaces:
a. Enclosure Required for Elevators Having
a. General Requirements. A permanent safe
Non Fire-Resistive Hoistway Enclosure.
and convenient means of access to elevator
Spaces containing machines, control
machine rooms and overhead machinery
equipment, sheaves, and other machinery
spaces shall be provided for authorized
shall be enclosed with non combustible
persons.
material extending to a height of not less
than 1 830 mm. Openwork material, if used, Where the passage is over a sloping roof
b.
shall reject a ball 51 mm in diameter. having slope exceeding 15 degrees from the
horizontal, an unobstructed, permanent and
4.2 Equipment in Machine Rooms
substantial walkway not less than 610 mm
wide, equipped on at least one side with a
a. Equipment Permitted in Machinery and
standard railing not less than 1 067 mm
Control Spaces. Elevator machine and
high, shall be provided from the building exit
control equipment may be located in a room
door at the roof level to the means of access
or space containing other machinery and
to machine room or machinery spaces.
equipment essential to the operation of the
Railings shall conform to the requirements
building; provided that they are separated
of ANSI A12.1.
from the other machinery or equipment by a
substantial metal grille enclosure not less 4.7 Headroom in Machine Rooms and Overhead
than 1 830 mm high with a self-closing and Machinery Spaces. Elevator machine rooms
self-locking door. The grille enclosures shall
and machinery spaces not located over the
be of a design which will reject a baIl 51 mm
hoistway shall have a clear headroom of not
in diameter.
less than 2 130 mm.
b. Equipment Prohibited in Machine Room.
Where a floor is provided at the top of the
Where the elevator machine and control
hoistway (see Sec. 4.2), elevator machine
equipment are not located at the top of the
rooms and overhead machinery spaces above
hoistway, only machinery and equipment
such floor shall have a clear headroom of not
required for the operation of the elevator
less than the following:
shall be permitted in the elevator machine
room.
a. Machine, control, and motor-generator
rooms, 2 130 mm.
4.3 Where machine room are provided over elevator
shaftways they shall be substantially b. Spaces containing overhead, secondary or
constructed with sufficient room for repair and
deflecting sheaves, and governors, signal
inspection and access shall be by means of iron
machines, or other equipment, 1 372 mm.
ladder or stairs where the machine room
entrance is more than 610 mm above the
c. Spaces containing overhead, secondary and
adjacent floor or roof surface. The angle of
deflecting sheaves, the machine and
incline of such ladder or stair shall not exceed
supporting beams may encroach on the
60° horizontal.
required headroom provided there is a
clearance of not less than 914 mm between
4.4 Landing doors for power driven elevators shall
the underside of such beams and the top of
be provided with interlocks to hold the elevator
the floor.
car immovable while any landing. door is open
and to make it impossible to open any landing
door when the car is more than 80 mm away
71
__
CHAPTER 6- ELEVATORS, DUMBWAITERS, ESCALATORS AND MOVING WALKS
x
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Bracket g. Se4 Page 7
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Moment of Inertia, in
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Moment of Inertia, in.
4.8 Lighting and Ventilation of Machine Room Where practicable the light control switch
and Machinery Spaces. shall be located on the lock jamb side of the
access door.
(a) Lighting. Permanent electric lighting shall
be provided in all machine rooms and (b) Ventilation for Machinery and Control
machinery spaces. Equipment. Machine rooms shall be
provided with natural or mechanical
The illumination shall be not less than 108 ventilation to avoid overheating of the
lux at the floor level, The lighting control electrical equipment and to insure safe and
switch shall be located within easy reach of normal operation of the elevator.
the access to such rooms or spaces.
72
CHAPTER 6- ELEVATORS, DUMBWAITERS, ESCALATORS AND MOVING WALKS
4.9 Storage of Materials in Machine and Control (a) All risers and returns shall be located
Room. Elevator machine and control rooms outside these spaces.
shall be maintained free of refuse, and shall not
be used for the storage of articles unnecessary (b) Branch lines in hoistway shall supply
for the maintenance or operation of the elevator. sprinklers at not more than one floor
Flammable liquids having a flash point of less level.
than 43.3°C shall not be kept in such rooms.
(c) Shut off valves shall be provided in
Section 5.0 Electrical Wiring, Pipes, and accessible locations outside these
Ducts in Hoistway and Machine Rooms spaces.
5.1 Wiring, Raceways, and Cables in Hoistways. 4. Piping for pit and sump pumps may be
Main feeders for supplying power to the elevator installed.
shall be installed outside the hoistway.
5.3 Guarding of Exposed Auxiliary Equipment:
Only such electrical wiring, raceways, and
cables used directly in connection with the a. In machine rooms and secondary machinery
elevator, including wiring for signals, for spaces, exposed gears, sprockets, tape of
communication with the car, for lighting, heating, rope sheaves or drums of selectors, floor
air conditioning, and ventilating the car, for low- controllers or signal machines, and their
voltage fire-detecting systems, for pit sump driving ropes, chains or tapes, shall be
pumps, and for heating and lighting the guarded to protect against accidental
hoistway, may be installed inside the hoistway. contact.
1. The construction of the pit walls, the e. Stop Switch in Pits. There shall be
pit floor, and any pit access doors installed in the pit of each elevator an
74
CHAPTER 6- ELEVATORS, DUMBWAITERS, ESCALATORS AND MOVING WALKS
75
CHAPTER 6 ELEVATORS, DUMBWAITERS, ESCALATORS AND MOVING WALKS
76
CHAPTER 6- ELEVATORS, DUMBWAITERS, ESCALATORS AND MOVING WALKS
(a) Horizontal slide, single or multi- f. The vision panels in horizontally swinging
section. doors shall be located for convenient vision
when opening the door from the car side.
(b) Swing, single-section.
g. Wire-glass panels in power-operated doors
(c) Combination horizontal slide shall be substantially flush with the surface
and swing. of the landing side of the door.
77
CHAPTER 6- ELEVATORS, DUMBWAITERS, ESCALATORS AND MOVING WALKS
(b) The top surface or beveled sills 1. Stops shall be provided in the
shall not be more than 38 mm entrance assembly to prevent
above the adjacent floor hangers from over-running the end
surface. of the track.
78
CHAPTER 6- ELEVATORS, DUMBWAITERS, ESCALATORS AND MOVING WALKS
applied to the panel surface for transmitted to the rails as a result of loading
decorative purposes. and unloading operations.
6. The entrance assembly shaH be capable d. Panels. Panels shall conform to the
of withstanding, a force of 113 kg following:
applied on the landing side at right
angles to and approximately at the 1. The panels shall be constructed of
center of a panel. This force shall be noncombustible material.
distributed over an area of
approximately 102 mm by 102 mm. Exception: A structural core made of
There shall be no appreciable combustible material may be used if
permanent displacement or deformation covered with not less than 0.455
of any parts of the entrance assembly mm sheet metal.
resulting from this test.
(a) The lower panel of vertical
7. If any combustible material or low biparting entrances and the top
melting point material, is used in the of the panel of vertical slide
entrance assembly, should be entrances which slide down to
consumed or should melt, the allowable open, shall be provided with a
movement towards the hoistway of the truckable sill designed for the
panels from their normal operating loads specified in Section
position shall not exceed 16 mm at the 6.3.9.9 (a) (1). Provisions shall
top or at the bottom. be made to transmit the panel
sill to the building structure.
5.12 Entrance, Vertical Slide Type
(b) Panels of biparting
a. Landing Sills. Landing Sills shall: counterbalanced entrances
shall conform to the following:
(a) be of metal and of
sufficient strength to (c) They shall be provided with
support the loads to be means to stop the closing
carried by the sills when panels when the distance
loading and unloading car between the closing rigid
can be secured in place. members of the panel is not
less than 19 mm.
(b) be firmly anchored to the
building structure in (ci) A fire-resistive, non-shearing,
substantially the same and non-crushing member of
place as the elevator either the meting or overlapping
landing floor. type shall be provided on the
upper panel to close the
b. Entrance Frames. The uprights and lintels distance between the rigid door
used to frame the opening shall be securely sections when in contact with
fastened to the building structure at the top the stops.
and bottom and to the wall.
(e) Rigid members which overlap
c. Rails. The panel guide rails shall be the melting edge and center
securely fastened to the building structure latching devices are prohibited.
and the entrance frame, at intervals,
throughout their entire length. (f) The panels with their
attachments shall overlap the
Rails and their supports shall withstand the entrance frame and sill by not
forces specified in Section 6.3.9.1 (d) (6). less than 51 mm in the closed
Where truckable sills are provided as position.
specified in Section 6.3.9.1 (ci) (2), the rails
shall withstand any reactions which may be (g) The clearance between a panel
and the frame lintel, between a
79
CHAPTER 6- ELEVATORS, DUMBWAITERS, ESCALATORS AND MOVING WALKS
80
CHAPTER 6- ELEVATORS, DUMBWAITERS, ESCALATORS AND MOVING WALKS
used subject to the following requirements: 11.91 61.91 88.90 15.88 31.75 7.94
16.37 88.90 114.3 15.88 38.10 7.94
1. They shall have a section modulus 17.86 88.90 127.0 15.88 44.45 7.94
and moment of inertia equal to or 22.32 88.90 127.0 15.88 50.01 12.70
greater than that of the section 27.53 107.95 139.7 19.05 50.01 12.7
shown in Fig. 6.D.1.3 for a given 33.48 101.60 139.7 28.58 50.80 14.29
loading condition. 44.65 127.00 139.7 38.10 57.15 17.46
81
CHAPTER 6- ELEVATORS, DUMBWAITERS, ESCALATORS AND MOVING WALKS
2. With Two (Duplex) Car or 6.2.1 Rail Joints and Fish plates
Counterweight Safeties. Where
the car or counterweight is provided a. Type and Strength of Rail Joints. Metal
with two safety devices, the loads guide rail sections shall be joined together
specified in Fig. 6.D.1.4 (a) (1) may as specified in 6.D.1.4 (b).
be increased by the factors
specified in Table 6.D.1.4 (b). b. Design and Construction of Rail Joints.
The joints of metal guide rails shall conform
3. Counterweight With No Safety. to the following requirements:
Guide rails for counterweights not
provided with a safety device shall Table 6.D.1.4 (b)
be fastened to the building structure Load Multiplying Factor for Duplex Safeties
at intervals not more than 4 880
mm, and the weight of the Vertical Distance bet. Multiply Load in
counterweight for each size of guide Safeties, Fig. 6.4.1.4 (a) (1) by
rail shall not exceed that specified in 18 or more ft. 2.00
Table 6.D.1.4 (c)(1). 15ft 1.83
12ft 1.67
Intermediate tie brackets, 9ft 1.50
approximately equally spaced, shall
be provided between the guide rails Table 6.D.1.4 (c) (I)
at intervals as specified in Table Guide Rails for Counterweight Without Safeties
6.D.1.4 (c) (2).
Max. Bracket
Intermediate tie brackets are not Weight of Nominal Weight
Spacing without
required to be fastened to the Counterweight, Of guide rail,
Reinforcement,
building structure. kg kg/rn rn
6,804.0 11.91 4.88
Exception: The bracket spacing 12,247.2 16.37 4.88
specified may be increased by an 17.86 4.88
13,154.4
amount determined by Figs. 6.D.1.4
18,144.0 22.32 4.88
(a) (1) and 6.D.1.4 (a) (2), subject to
25,401.6 27.53 4.88
the following requirements:
36,288.0 33.48 4.88
(a) Where guide rails are reinforced
or a larger rail section is used
having a moment of inertia Table 6.0.1.4 (c) (2)
about an axis parallel to the Intermediate Tie Brackets
base [axis x-x Fig. 6.D.1.4 (a)
(2)], at least equal to that of the Nominal Distance Bet. No. of Intermediate
rail sections shown in Table Fastening to Building Tie Brackets
6.D.1.3, based on the weight of Structure, cm
the counterweight; and 0to366 0
366 to 427 1
(b) Where intermediate tie 427 to 488 2
brackets, approximately equally
spaced, are provided between NOTE:
the guide rails at intervals of not m = ftx0.305
over 2 130 mm. kg = lbxO.454
kg/rn = Ib/ftxl.49
6.2 Brackets, Fastenings, and Supports. The
guide rail brackets, their fastenings and 1. The ends of the rails shall be
supports, such as building beams and walls, accurately machined with a tongue
shall be capable of resisting the horizontal and matching groove centrally
forces imposed by the class of loading with a located in the web.
total deflection at the point of support not in
excess of 3 200 mm.
82
CHAPTER 6- ELEVATORS, DUMBWAITERS, ESCALATORS AND MOVING WALKS
33.48 19.05
44.65 19.05
Table 6.D.1.6 (b)
Minimum Thickness of Fish plates, and
Minimum Diameter of Fastening Bolts d.. Type of Fastening. Guide rail shall be
secured to their brackets by clips, welds or
Nominal Weight bolts.
Mm. Thickness Mm. Diameter of
kg/m of Fish Plates, Bolts, mm
Bolts used for fastening shall be such
mm
strength as to withstand the forces specified
11.91 14.29 12.70 in Section 6.D.1.5.
16.37 17.46 15.88
17.86 7.46 15.88 Size of Bolts for Fastenings. The size of
e.
22.32 17.46 15.88 bolts used for fastening the guide rails or rail
27.53 20.64 19.05 clips to the brackets shall be not less than
33.48 — 20.64 19.05 specified in Table 6.D.1.9.
44.65 20.64 19.05
f. Bolt Holes for Fastening. The diameter of
4. The width of the fishplates shall be holes or the width of slots for fastening bolts
not less than the width of the back shall not exceed the diameter of the bolt by
of the rail. more than 1.6 mm.
5. The thickness of the fishplates and 6.2.2 Car and Counterweight Buffers
the diameter of the bolts for each
size of guide rail shall not be less a. Spring, Oil, or Equivalent Buffers. Buffers
than specified in Table 6.D.1.4 (b). of the spring, oil, or equivalent type shall be
installed under cars and counterweights of
6. The diameter of bolt holes shall not passenger and freight elevators.
exceed the diameter of the bolts by
more than 1.6 mm for guide rails nor Spring buffers or their equivalent may be
3 200 mm for fishplates. used where the rated speed is not in excess
of 1.02 m/s.
Exception: Joints of different design and
construction may be used subject to the Exception: Where type C safeties are used
approval of the enforcing authority, (see Sec. 6.D.6.7 (a), car buffers are not
provided they are equivalent in strength required provided solid bumpers are
and will adequately maintain the installed.
accuracy of the rail alignment.
b. Location. Buffers or bumpers shall be
c. Bracket Fastenings. Guide-rail brackets located so as to retard the car and
shall be secured to their supporting structure counterweight without exceeding allowable
by means of bolts, rivets, or by welding. design stresses in the car frame and
Fastening bolts and bolt holes in brackets counterweight frame.
and their supporting beams shall conform to
the requirements of Sections 6.D.1.8 to c. Construction and Requirements for Solid
6.D.1.10. Bumpers. Solid bumpers used with Type C
safeties shall be made of wood or other
suitably resilient material of sufficient
strength to withstand without failure and
83
CHAPTER 6- ELEVATORS, DUMBWAITERS, ESCALATORS AND MOVING WALKS
impact of the car with rated load, or the 1. Retardation. Oil buffers shall
counterweight, descending at governor develop an average retardation not
tripping speed. 2 and shall
in excess of 9.81 rn/s
develop no peak retardation greater
The material used shall be of a type which 2 having a duration
than 24.54 m/s
will resist deterioration or be so treated as to exceeding 1/25 sec with any load in
resist deterioration. the car from rated load to a
minimum load of 68 kg when the
d. Construction and Requirements for buffers are struck with an initial
Spring Buffers. speed.
84
CHAPTER 6- ELEVATORS, DUMBWAITERS, ESCALATORS AND MOVING WALKS
Tests shaH be made on a buffer (1) For car oil buffers, the total
of each type or design to be weight of the car as marked
approved and having the on the car crosshead data
following oil porting: plate plus 68 kg.
(b) The porting having the range of (2) For counterweight oil
maximum loads for which the buffers, the weight of the
buffer is designed. counterweight used.
(c) The porting having the range of (b) The maximum load rating shall
minimum loads for which the be not less than:
buffer is designed.
(1) For car oil buffers, the total
The firm or person installing the weight of the car as marked
buffer shall submit to the on the cross head data
enforcing authority an authentic plate plus the rated load;
copy of the test certificate.
(2) For counterweight oil
5. Upon receipt of an authentic copy of buffers, the weight of the
the test certificate stating that the counterweight used.
buffer tested has met the specified
test requirements, the enforcing 7. Buffer Marking Plate. Every
authority shall approve the use of installed oil buffer shall have
such buffers. Oil buffers tested in permanently attached thereto a
accordance with the test metal plate, marked by the
requirements of prior editions of this manufacturer in a legible and
Code shall be acceptable without permanent manner, indicating:
being re-tested, on submittal by the
person or firm installing the buffers (a) the maximum and minimum
of the test certificate stating that the loads and the maximum striking
buffer, when tested, met the speeds for which the buffer may
specified test requirements of that be used in conformity with this
edition of the Code. The approval section;
shall include buffers of the same
type or design having a greater or (b) the permissible range in
shorter stroke, up to a maximum of viscosity of the buffer oil to be
2 130 mm and having oil porting for used, stated in Saybolt Seconds
any load range within the maximum Universal at 37.8°C;
and minimum loads for which the
buffer has been tested, provided (c) the viscosity index number of
that the installer certifies on the the oil to be used;
plans and specifications filed with
the enforcing authority that the (d) the pour point in degrees
buffer as installed will conform to Centigrade of the oil to be used.
the requirements of Section 6.D.2.5
(a). 6.2.3 Counterweights
85
CHAPTER 6 - ELEVATORS, DUMBWAITERS, ESCALATORS AND MOVING WALKS
2. Tie Rods. At least two tie rods shall When compensating ropes are used with a
be provided which shall pass tension sheave, one end of each rope shall
through all weight sections. Tie rods be provided with a shackle rod, or other
shall be provided with lock nut and means which provide for individual
cotter pins at each end. adjustment or rope length.
Exception: Tie rods are not required 6.2.4 Car Frames and Platforms
where other means are provided to
retain weight sections in place if a. Car Frames Required. Every elevator shall
they become broken. have a car frame (see Section 6.B
definitions).
3. Guiding Members. Counterweight
frames shall be guided on each b. Guiding Members. Car frames shall be
guide rail by upper and lower guided on each guide rail by upper and
guiding members attached to the lower guiding members attached to the
frame. frame.
6.2.4 Design Requirements for Frames and c. Design of Car Frames and Guiding
Rods. Members. The frame and its guiding
members shall be designed to withstand the
a. Material. Frames and rods shall be made of forces resulting under the loading conditions
steel or other metals, provided that where for which the elevator is designed and
steels of greater strength than those installed (see Section 6.D.8).
specified, or where metals other than steel
are used, the factor of safety used in the d. Underslung or Sub-Post Frames. The
design shall conform to the requirements of vertical distance between the center lines of
Section 6.D.3.2 (c). the top and bottom guide shoes of an
elevator car having a sub-post car frame or
b. Factor of Safety. The frame members and having an underslung car frame located
their connections shall be designed with a entirely below the car platform, shall be not
factor of safety of not less than 5 with the less than 40% of the distance between
elevator at rest and the counter-weight at guide rails.
the top of its travel.
e. Car Platforms. Every elevator car shall
c. Sheaves. Where a hoisting sheave or have a platform consisting of a non
sheaves are mounted in the frame, the perforated floor attached to a platform frame
requirements of Sec. 6.D.4.9 shall apply supported by the car frame, and extending
(see also Sec. 6.D.9.2 and 6.D.9.3 for over the entire area within the car enclosure.
requirements for sheaves). The platform frame members and the floor
shall be designed to withstand the forces
d. Suspension-Rope Hitch or Shapes. developed under the loading conditions for
Where counterweights are suspended by which the elevator is designed and installed.
ropes attached directly to the frames by
means of rope fastenings, the rope Exception: Laminated platforms may be used for
attachments shall conform to Section passenger elevators having a rated load of 2270
6.D.4. 10. kg or less. The deflection at any point of a
laminated platform when uniformly loaded to
e. Securing of Weights in Fames. Filler rated capacity, shall not exceed 1/960 of the
weight of counterweight shall be made of span. The stresses in the steel facing shall not
cast iron in a slab form where it should be exceed 1/5 of its ultimate strength and the
tied rigidly to the frame by tie-rods. stresses in the plywood core shall not exceed
60% of the allowable stresses in Section 3.14 of
f. Compensating Chain or Rope the American Plywood Association Plywood
Fastenings. Compensating chains or ropes Design Specification. Platform frames are not
shall be fastened to the counterweight frame required where laminated platforms are
directly or to a bracket fastened to the frame provided.
and shall not be fastened to the tie rods.
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CHAPTER 6- ELEVATORS, DUMBWAITERS, ESCALATORS AND MOVING WALKS
f. Materials for Car Frames and Platform adequately reinforced and braced to the car
Frames. Materials used in the construction platform and conforming to the following:
of car frames and platforms shall conform to
the following: 1. It shall extend not less than the full
width of the widest hoistway-door
1. Car frames and outside members of opening.
platform frames shall be made of
steel or other metals. 2. It shall have a straight vertical face,
extending below the floor surface of
2. Platform stringers of freight the platform, of not less than the
elevators designed for Class B or C depth of the leveling or truck zone,
loading shall be of steel or other plus 76 mm.
metals.
3. The lower portion of the guard shall
3. Platform stringers of passenger be bent back at an angle of not less
elevators and of freight elevators than 60° nor more than 75° from the
designed for Class A loading shall horizontal.
be made of steel or other metals, or
of wood. 4. The guard plate shall be securely
braced and fastened in place to
g. Cast iron shall not be used for any part withstand a constant force of not
subject to tension, torsion or bending. less than 68 kg applied at right
angles to and at any position on its
1. Guiding supports face without deflecting more than
6.3 mm, and without permanent
2. Guide shoes deformation.
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CHAPTER 6- ELEVATORS, DUMBWAITERS, ESCALATORS AND MOVING WALKS
1. They shall be provided with electric d. Top Emergency Exits. An emergency exit
contacts which will prevent with a cover shall be provided in the top of
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CHAPTER 6- ELEVATORS, DUMBWAITERS, ESCALATORS AND MOVING WALKS
all elevator cars and shall conform to the passengers in case the glass panels
following requirements: break or are dislodged.
1. The exit opening shall have an area 4. Be so mounted in the structure, that
of not less than 0.258 m
, and shall
2 the structure including the glass in
measure not less than 406 mm on place shall withstand the required
any side. elevator tests without damage.
Exception: [Sec. 6.D.5.4 (c)]: The a. Illumination and Outlets Required. Cars
exit cover of a lower deck of a multi- shall be provided with an electric light or
deck elevator can be opened from lights conforming to the following:
either compartment.
1. Not less than two lamps shall be
6.2.7 Car-Enclosure Tops. Tops of car enclosures provided.
shall be so designed and installed as to be
capable of sustaining a load of 136 kg on any 2. The minimum illumination at the car
square area 610 mm on a side and45 kg threshold, with the door closed,
applied at any point. Simultaneous application shall not be less than:
of these loads is not required.
(a) For passenger elevators: 54 lux
a. Equipment Prohibited on Top of Cars. A
working plafform or equipment which is not (b) For freight elevators: 27 lux
required for the operation of the elevator or
its appliances, except where specifically 3. Passenger elevators shall be
provided herein, shall not be located above provided with an emergency lighting
the top of an elevator car. power source on each elevator
conforming to the following:
b. Glass in Elevator Cars. Glass may be used
in elevator cars. Glass exceeding 0.093 m
2 (a) The emergency system shall
in area shall: provide some general
illumination in the car. The
1. Be laminated; intensity of illumination 1220
mm above the car floor and
2. Meet the requirements for laminated approximately 305 mm in front
glass of ANSI Z97.1 except as to of the car operating device shall
transparency; be not less than 22 lux. Lights
shall be automatically turned on
3. Be installed and guarded so as to in all elevators in service
provide adequate protection for immediately after normal car
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CHAPTER 6- ELEVATORS, DUMBWAITERS, ESCALATORS AND MOVING WALKS
lighting power fails. The power shall be located within or below the lower
system shall be capable of members of the car frame (safety plank).
maintaining the above light
intensity for a period of at least All car safeties shall be mounted on a single
4 hours. car frame and shall operate only on one pair
of guide rails between which the frame is
(b) Not less than two lamps of located.
approximately equal wattage
shall be used. b. Duplex Safeties. Where duplex (two)
safeties are provided, the lower safety
4. Each elevator shall be provided with device shall be capable of developing not
an electric light and convenience less than one-half of the force required to
outlet fixture on the car top. stop the entire car with rated load (see Sec.
6.4.8.8). Duplex safety devices shall be
b. Passenger-Car Lighting Devices. Glass arranged so as to function approximately
used for lighting fixtures shall conform to the simultaneously. Type A or Type C safety
requirements of Section 6.D.5.7. devices (see Sec. 6.4.6.4) shall not be used
in multiple (duplex).
Suspended glass used in lighting fixtures
shall be supported by a metal frame secured c. Counterweight Safeties. Counterweight
at not less than three points. Fastening safeties shall conform to the requirements
devices shall not be removable from the for car safeties.
fixture. Glass shall not be drilled for
attachment. Light through supporting wiring Exceptions:
raceways and other auxiliary lighting
equipment, where used, shall be of metal 1. Where otherwise specified in Sec.
except where lined with non combustible 6.4.6.
materials.
2. For rated speeds of not over 0.76
Lighting arrangements using slow-burning m/s, counterweight safeties may be
combustible materials for diffusing and operated as a result of the breaking
illumination purposes shall be permitted or slackening of the suspension
providing such combustible materials do not ropes and may be of the inertia or
come in contact with lighting equipment. other approved types without
governors (see Sec. 6.4.6.6 and
c. Protection of Light Bulbs and Tubes. 6.4.7).
Light bulbs and tubes shall be:
3. A switch operated by the safety
1. Installed and guarded so as to mechanism is not required for
provide adequate protection incase counterweight safeties (se Sec.
the bulb or tube in the structure, 6.D.6.6).
shall withstand the required elevator
tests without damage. d. Identification and Classification of Types
of Safeties. Car safety devices (safeties)
2. So mounted in the structure, that are identified and classified on the basis of
the structure including the bulb or perlormance characteristics after the safety
tube in the structure, shall withstand begins to apply pressure on the guide rails.
the required elevator tests without On this basis, there are three types of
damage. safeties:
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CHAPTER 6- ELEVATORS, DUMBWAITERS, ESCALAT.ORS AND MOVING WALKS
from the mass and the motion of the shall conform to the requirements of
car or the counterweight being Section 6.D.7.5.
stopped. These safeties apply
pressure on the guide rails through g. Type A (Instantaneous) Safeties. Type A
eccentrics, rollers or similar devices, safeties may be used on elevators having a
without any flexible medium rated speed of not more than 0.76 m/s.
purposely introduced to limit the When over-speeding occurs, with the
retarding force and increase the hoisting rope intact, such safeties shall be
stopping distance. actuated by the governor.
2. Type B Safeties. Safeties which On the parting of the hoisting ropes (free
apply limited pressure on the guide fall), type A governor operated safeties shall
rails during the stopping interval, apply without appreciable delay, and their
and which provide stopping application shall be independent of the
distances that are related to the speed action of the governor and of the
mass being stopped and the speed location of the break in the hoisting ropes
at which application of the safety is (inertia application), and may be
initiated. Retarding; forces are accomplished by the use of a governor and
reasonably uniform after the safety governor rigging having a sufficiently high
is fully applied. Continuous tension value of inertia to apply the safety on free
in the governor rope may or may not fall independently of the speed action of the
be required to operate the safety governor.
during the entire stopping interval.
1. Type C (Combination
3. Type C Safeties (type A with Oil Instantaneous and Oil Buffer
Buffers). Safeties which develop Safety). Type C safeties may be
retarding forces during the used subject to the following
compression stroke of one or more requirements:
oil buffers interposed between the
lower members of the car frame and (a) The rated speed shall be not
a 9overnor-operated type A auxiliary more than 2.54 m/s.
safety plank applied on the guide
rails. The stopping distance is (b) The oil buffers shall conform to
equal to the effective stroke of the aB requirements specified in
buffers. Section 6.D.2 for oil buffers,
except that the stroke shall be
e. Safeties to Stop Ascending Cars or based on governor tripping
Counterweight Prohibited. Safeties shall speed and on an average
not stop an ascending car or counterweight. retardation not exceeding 9.81
.
2
rn/s
f. Governor-Actuated Safeties and Car-
Safety Mechanism Switches Required. (c) After the buffer stroke, as
defined in Sec. 6.D.6.7 (2) has
1. Car safeties, and counterweight been completed, provision shall
safeties, where provided, shall be be made for an additional travel
actuated by separate speed of the plunger or piston of not
governors. less thanl0% of the buffer
stroke to prevent excessive
Exception: Speed governor are not impact on the buffer parts and
required for the operation of the auxiliary safety plank.
counterweight safeties of elevators
having a rated speed of not more (d) Where the distance between
than 0.76 m/s. guide rails exceeds 2 440 mm,
the safety shall be provided with
2. Every car safety shall be provided two oil buffers of substantially
with a switch, operated by the car identical calibration, and the
safety mechanism. This switch buffers shall be so located as to
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CHAPTER 6- ELEVATORS, DUMBWAITERS, ESCALATORS AND MOVING WALKS
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CHAPTER 6- ELEVATORS, DUMBWAITERS, ESCALATORS AND MOVING WALKS
e. Speed Governor Over-Speed and Car d. Governor Rope Tag. A metal data tag shall
Safety-Mechanism Switches be securely attached to the governor rope
fastening. This data tag shall bear the
1. Where Required. A switch shall be following wire rope data:
provided on the speed governor and
operated by the over-speed action 1. The diameter in mm.
of the governor when used with type
B and C car safeties of elevators 2. The manufacturer’s rated breaking
having a rated speed exceeding strength.
0.76 m/s. A switch shall be provided
on the speed governor when used 3. The grade of material used.
with a counterweight safety for any
car speed. 4. The month and year the rope was
installed.
For static control, an over-speed
switch shall be provided regardless 5. Whether non-preformed or pre
of rated speed and shall operate in formed.
both directions of travel.
6. Construction classification.
Every car safety shall be provided
with a switch operated by the car 7. Name of the person or firm who
safety mechanism when the safety installed the rope.
is applied.
8. Name of the manufacturer of the
These switches when operated shall rope. A new tag shall be installed at
remove power from the driving- each rope renewal.
machine motor and brake before or
at the time of application of the e. Speed Governor Marking Plate. A metal
safety. plate shall be securely attached to each
speed governor and shall be marked in a
6.2.12 Governor Ropes legible and permanent manner with letters
and figures not less than 6.3 mm in height
a. Material and Factor of Safety. Governor indicating the following:
ropes shall be of iron, steel, monel metal,
phosphor bronze, or stainless steel. They 1. The speed in meter per minute at
shall be of regular-lay construction, and not which the governor is set and
less than 9.5 mm in dia. Tiller-rope sealed to trip the governor-rope-grip
construction shall not be used. The factor of jaws.
safety of governor ropes shall be not less
than 5. 2. The size, material and construction
of the governor rope on which the
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CHAPTER 6- ELEVATORS, DUMBWAITERS, ESCALATORS AND MOVING WALKS
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CHAPTER 6- ELEVATORS, DUMBWAITERS, ESCALATORS AND MOVING WALKS
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CHAPTER 6- ELEVATORS, DUMBWAITERS, ESCALATORS AND MOVING WALKS
2400
2300
2200
2100
2000
1900
1800
1700
1600
E 1500
0
1400
0)
> 1300
1200
1100
0)
>
0
0 1000
900
800
700
600
500
400
300
200
100
200 400 600 800 1000 1200 1400 1600 1800 2000
0
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CHAPTER 6- ELEVATORS, DUMBWAITERS, ESCALATORS AND MOVING WALKS
7. The car safeties shall be designed 6.3.1 Driving Machines and Sheaves
to stop and hold the specified
“Capacity Lifting One-Piece Loads,” a. Type of Driving Machines
with the ropes intact.
1. All driving machines shall be of the
8. Where there is an occupied space, traction type.
or an unauthorized access under
the hoistway, the following Exceptions:
requirements shall be conformed to:
(a) Winding-drum machines may be
(a) The machine shall be designed used for freight elevators subject to
to operate with the “Capacity the if:
Lifting One-Piece Loads” at
slow speed; the car safety shall 1. They shall not be provided with
be designed to stop and hold counterweights.
the car with this load
independently of the hoisting 2. The rated speed of elevator
ropes; shall not exceed 0.25 m/s.
(b) The counterweight safety, shall 3. The travel of the elevator car
be designed to stop and hold shall not exceed 12.2 m.
the entire weight of the
counterweight independently of (b) Screw nachines conforming to the
the ropes. require nents of Section 6.D.9.5.
9. For traction machines, where b. Material and Grooving for Sheaves and
necessary to secure adequate Drums. Sheaves and drums used with
traction, additional counterweight suspension and compensating ropes shall:
shall be added during the period of
use with one-piece loads so that the 1. Be of metal and provided with
total over-balance is at least equal finished grooves for ropes. The
to 45% of the “Capacity Lifting One- grooves of sheaves not used to
Piece Loads.” transmit power may be lined with
non-metallic material. The grooves
10. A special operating device of the of sheaves used to transmit power
car-switch or continuous-pressure may be lined with non-metallic
type shall be provided in the material provided that in the event
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CHAPTER 6- ELEVATORS, DUMBWAITERS, ESCALATORS AND MOVING WALKS
the lining should fail, there will be shall be provided unless other
sufficient traction still available in means are provided to limit the
the groove to safely stop and hold down speed of the car with rated
the car with 125% of the rated load. load to not over 0.89 m/s if there is
a failure of the driving means.
2. Have a pitch diameter of not less
than: 3. Where belts or chains are used to
connect the motor to the driving
(a) 40 times the diameter of the machines the following
rope, where used with requirements shall be conformed to:
suspension ropes;
(a) Belts shall be of the multiple V
(b) 32 times the diameter of the belt type.
rope, where used with
compensating ropes. (b) Two or more separate chains
shall be provided.
c. Factor of Safety for Driving Machines
and Sheaves. The factor of safety, based (c) The driving means, whether
on the ultimate strength of the material, to belts or chains, shall have a
be used in the design of driving machines factor of safety of not less than
and in the design of sheaves used with 10.
suspension and compensating ropes shall
be not less than: (d) The machine brake shall be so
located that failure of the driving
1. 8 for steel, bronze, or for other belt or chain will not prevent it
metals having an elongation of at from performing its intended
least 14% in a length of 51 mm. function.
2. 10 for cast iron, or for other metals 4. The factor of safety of the screw as
having an elongation of less than a column shall be not less than 3
14% in a length of5l mm. based on the total weight supported
with rated load in the car.
The load to be used in determining
the factor of safety shall be the 5. Means shall be provided to maintain
resultant of the maximum tensions the screw in its vertical position in
in the ropes leading from the case of excessive over-travel.
sheave or drum with elevator at rest
and with rated load in the car. 6. Screws shall be of steel and nuts
shall be of bronze or other material
d. Driving-Machine Brakes. The elevator having an elongation of at least 14%
driving machine shall be equipped with a inalength of 51 mm.
friction brake applied by a spring, or by
gravity, and released electrically. The brake 7. A vertical casing, closed at the
shall be designed to have a capacity bottom, shall be provided to enclose
sufficient to hold the car at rest with its rated and protect the screw below the nut.
load [see also Sec. 6.D.8.8.J.
6.3.2 Terminal Stopping Devices
e. Screw Machines. Screw machines shall be
of the uncounterweighted type and shall a. Additional Requirements for Winding
conform to the requirements of the section Drum Machines. Final terminal stopping
and to the following: devices for winding-drum machines shall
conform to the following:
1. The rated speed shall not exceed
0.25 m/s. 1. Stopping switches, located on and
operated by the driving machine,
2. A car safety device conforming to shall not be driven by chains, ropes,
the requirements of Section 6.4.6 or belts.
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CHAPTER 6- ELEVATORS, DUMBWAITERS, ESCALATORS AND MOVING WALKS
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CHAPTER 6 - ELEVATORS, DUMBWAITERS, ESCALATORS AND MOVING WALKS
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CHAPTER 6- ELEVATORS, DUMBWAITERS, ESCALATORS AND MOVING WALKS
a
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CHAPTER 6- ELEVATORS, DUMBWAITERS, ESCALATORS AND MOVING WALKS
H 0 2.
two-way conversation for at
least 4 hrs.
*
Operation and Signaling
(a) A telephone connected to a
central telephone exchange
system.
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CHAPTER 6 - ELEVATORS, DUMBWAITERS, ESCALATORS AND MOVING WALKS
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CHAPTER 6- ELEVATORS, DUMBWAITERS, ESCALATORS AND MOVING WALKS
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CHAPTER 6- ELEVATORS, DUMBWAITERS, ESCALATORS AND MOVING WALKS
stalled elevator upon opening the car door, safety shall be based on the actual rope
can determine the floor position. speed corresponding to the rated speed of
the car.
6.4.13 Suspension Rope and their Connections.
f= SXN
6.4.13.1 Suspension Means. Elevator cars shall be w
suspended by steel wire ropes attached to
the car frame passing around sheaves The factor of safety shall be calculated by
attached to the car frame specified in the following formula:
Section 6.4.4.1.
N = number of runs of rope underload
Only iron (low-carbon steel) or steel wire (see Note)
ropes, having the commercial classification
“Elevator Wire Rope”, or wire rope S = manufacturer’s rated breaking
specifically constructed for elevator used for strength of one rope
the suspension of counterweights. The wire
material of ropes shall be manufactured by W = maximum static load imposed on all car
the open-hearth or electric furnace process ropes with the car and its rated load at
or their equivalent. any position in the hoistway
Exception: Elevators with screw machines. Note: In the case of multiple roping, the
number of runs of rope (N) under load
6.4.13.2 On Crosshead Data Plate. The crosshead will be: For 2:1 roping, twice the
data plate shall bear the following wire rope number of ropes used; for 3:1 roping,
data: three times the number of ropes used,
etc.
a. The number of ropes.
6.4.13.9 Minimum Number and Diameter of
b. The diameter in millimeter. Suspension Ropes. The minimum number
of hoisting ropes used shall be three for
c. The manufacturer’s rated breaking strength traction elevators, and two for drum-type
per rope in kilograms. elevators.
6.4.13.3 On Rope Data Tag. A metal data tag shall Where a car counterweight is used, the
be securely attached to one of the wire rope number of counterweight ropes used shall
fastenings. be not less than two.
6.4.13.4 Minimum number of hoisting ropes shall be The term “diameter” where used in this
three (3) for traction elevators and two (2) section shall refer to the nominal diameter
for drum-type elevators. as given by the rope manufacturer.
6.4.13.5 Suspension rope tension equalizers shall be The minimum diameter of hoisting and
provided. counterweight ropes shall be 9.5 mm.
6.4.13.6 Drum type elevators shall have not less than Table 6.4.13.8
one (I) turn of the rope on the drum when Minimum Factors of Safety for Suspension Wire Ropes
the car is resting on the fully compressed
buffers. Rope Speed in Feet per Minimum Factor of Safety
mm. (fpm) Passenger Freight
6.4.13.7 Suspension wire ropes shall not be 50 7.6 6.65
lengthened or repaired by splicing. 100 7.95 7.00
150 8.25 7.3
6.4.13.8 Factor of Safety. The factor of safety of the 200 8.6 7.65
suspension wire ropes shall be not less than 250 8.9 7.9
shown in Table 6.4.13.8 Fig. 6.4.13.8 gives 300 9.2 8.2
the minimum factor of safety for 350 9.5 8.45
intermediate rope speeds. The factor of 400 9.75 8.7
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CHAPTER 6- ELEVATORS, DUMBWAITERS, ESCALATORS AND MOVING WALKS
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CHAPTER 6- ELEVATORS, DUMBWAITERS, ESCALATORS AND MOVING WALKS
Grade60/30 for cast steel and shall be its outer edge be rounded and free from
stress relieved. cutting edges.
Exception: Steels of greater strength may be d. The diameter (d) of the hole at the large end
used provided they have an elongation of of the tapered portion of the socket shall be
not less than 20% in a length of 51 mm. not less than 2-1/4 times nor more than 3
times the diameter of the wire rope used.
e. Where the shackle rod is separate from the
rope socket, the fastening between the two Table 6.4.13.18
parts shall be positive and such as to Relation of Rope Diameter to Diameter of the
prevent their separation under all conditions Small Socket Hole
of operation of the elevator. Where the
connection of the two parts is threaded, the Nominal Rope Maximum Diameter of Hole
length of the thread engagement of the rod Diameter, in. (d’), in.
in the socket shall be not less than 1 1/2 3/8 to 7/16 inclusive 3/32 larger than nominal rope dia.
times the root diameter of the thread on the 1/2 to 3/4 inclusive 1/8 larger than nominal rope dia.
rod, and a cotter pin or equivalent means 7/8 to 1-1/8 inclusive 5/32 larger than nominal rope dia.
shall in addition be provided to restrict the 1-1/4 to 1-1/2 inclusive 3/16 larger than nominal rope dia.
turning of the rod in the socket and prevent
unscrewing of the connection in normal
operation. e. The diameter (dm) of the hole at the end of
the tapered portion of the socket shall be not
Eye bolts used as connections with clevis more than shown in Table 6.4.13.18.
type sockets shall be of forged steel
conforming to ANSI/ASTM A668, Class B Section 5.0 Hydraulic Elevators
(heat treated) without welds.
6.5.1 Hoistways, Hoistway Enclosures, and
f. Rope sockets shall be of such strength that Related Construction.
the rope will break before the socket is
materially deformed. 6.5.1.1 Hoistways, hoistway enclosures, and related
construction shall conform to the requirements
g. The shackle rod, eye bolt, or other means of the following Sections and Article 6.3.
used to connect the rope socket to the car except Sec. 6.3.7.
or counterweight, shall have a strength at
least equal to the manufacturer’s rated 6.5.2 Machine Rooms and Machinery Spaces
breaking strength of the rope.
6.5.2.1 Where pumps, motors, valves, and electrical
h. Rope fastenings incorporating anti-friction control equipment are located in spaces
devices which will permit free spinning of the separated from the hoistway enclosure (Sec.
rope shall not be used. 6.3.1.1), such spaces shall be separated from
other parts of the building by enclosures
6.4.13.17 Tapered Babbitted Rope Sockets. conforming to the requirements of Sec. 6.3.2.1
Tapered babbitted rope sockets shall be of a (a) and having an access door.
design as shown in Fig. 6.4.13.17, and shall
conform to the following: 6.5.3 Bottom and Top Clearances and Runby for
Cars and Counteweights
a. The axial length (I) of the tapered portion of
the socket shall be not less than 4-3/4 times 6.5.3.1 Bottom Car Clearance. The bottom car
the diameter of the tope used. clearances shall conform to the requirements
of Sec. 6.3.7.1, provided that, in the
b. The axial length (Lm) of the open portion of determination of the required clearance, any
the rope socket shall be not less than four under-car bracing which is located within 152
(4) times the diameter of the rope used. mm horizontally from the edge of the car
platform or 76 mm horizontally from the
c. The length of the straight bore (Lmm) at the centerline of the guide rails shall not be
small end of the socket shall be not more considered.
than 12.70 mm nor less than 3.2 mm, and
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CHAPTER 6 - ELEVATORS, DUMBWAITERS, ESCALATORS AND MOVING WALKS
6.5.3.2 Minimum Bottom and Top Car Runby. The 6.5.3.7 Top Clearance and Bottom Runby of
bottom and top car runby shall be not less Counterweights. Where a counterweight is
than: provided, the top clearance and the bottom
runby of the counterweight shall conform to
a. 76 mm for rated speeds not exceeding 0.51 the following:
m/s;
(a) Top Clearance. The top
b. 152 mm for rated speeds exceeding 0.51 clearance shall be not less than
rn/s the sum of the following:
6.5.3.3 Maximum Bottom and Top Car Runby. The (1) The bottom car runby.
bottom and the top car runby shall not be
more than 610 mm. (2) The stroke of the car buffers
used.
6.5.3.4 Top Car Clearance. The top car clearance
shall be not less than the sum of the following (3) 152 mm.
two items:
(b) Bottom Runby. The bottom
a. The top car runby. runby shall be not less than the
sum of the following:
b. The largest of the following:
(1) The distance the car can
1. 610 mm above the car crosshead travel above its top terminal
where a crosshead is provided. landing until the plunger
strikes its mechanical stop.
2. The height of the refuge space on
top of the car enclosure. (2) 152 mm.
6.5.3.5 Equipment Projecting Above the Car Top. 6.5.4 Protection of Spaces Below Hoistway
When the car reaches its maximum upward
movement and refuge space is provided, all 6.5.4.1 Where the space below the hoistway
equipment, exclusive of guide shoe is used for a passageway, is occupied
assemblies or gate posts for vertically sliding by persons, or, it is unoccupied, is not
gates, attached to and projecting above the secured against unauthorized access,
car top, shall be at least 152 mm from striking the following requirements shall be
any part of the overhead structure or any conformed to:
equipment located in the hoistway.
(a) The cylinder shall be supported
6.5.3.6 Overhead Obstructions in Hoistway. When by a structure of sufficient
overhead beams or other overhead hoistway strength to support the entire load
construction except sheaves are located that may be imposed upon it.
vertically over the car, but not over the
crosshead, the following requirements shall be (b) Where a counterweight is
met: provided, the space below it shall
be inaccessible to persons or the
a. The clearance from the car top to such counterweight shall be provided
beams or construction when the car is level with a safety device operated as
with the top landing shall be not less than a result of breaking or slackening
the amount specified in Sec. 6.5.3.4. of the counterweight suspension
ropes.
b. Such beams or constructions shall be
located not less than 610 mm horizontally
from the crosshead.
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CHAPTER 6- ELEVATORS, DUMBWAITERS, ESCALATORS AND MOVING WALKS
(c) The car shall be provided with 6.5.5.3 Counterweight Safeties. Counterweight
buffers of one of the following safeties, where provided in accordance with
types: the requirements of Sec. 6.5.4.1 (b), shall
conform to the requirements of Sec. 6.4.6,
1. Spring buffers of a design provided that safeties shall be operated as a
which will not be fully result of the breaking or slackening of the
compressed when struck by counterweight suspension ropes, irrespective
the fully loaded car at the of the rated speed of the elevator.
maximum speed attained in
the down direction. 6.5.5.4 Capacity and Loading. The requirements of
Section 6.4.8 covering capacity and loading
(d) Car buffer supports shall be shall apply to hydraulic elevators, provided
provided which will withstand that with Class C2 loading the load during the
without permanent deformation loading and unloading shall not exceed the
the impact resulting from buffer rated load of the elevator unless all parts of
engagement by the car with its the hydraulic equipment are designed for the
rated load at the maximum speed maximum pressure developed as a result of
attained in the down direction. this load.
6.5.5.1 Information on Elevator Layout. Elevator 6.5.6.1 Driving Machine and Connection
layout drawings shall, in addition to other data,
indicated the following: a. Type of Driving Machine. The machine
shall be of a direct plunger type or indirect
a. The bracket spacing. plunger (suspension type).
6.5.5.2 Car Safeties. Car safeties where provided (a) Ropes shall correspond to the
shall conform to the requirements of Section following conditions:
6.4.6 and to the following:
(1) The nominal diameter of the
a. The safety shall be of a type which can be ropes shall be at least 8 mm
released only by moving the car in the up
direction. (2) The tensile strength of the
wire shall be:
b. The switches required by Sec. 6.4.7.5 shall,
when operated, remove power from the 2.1 1570 N/mm or
driving machine motor and control valves 1770 N/mm for
before or at the time of application of the ropes of single
safety. tensile.
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CHAPTER 6 - ELEVATORS, DUMBWAITERS, ESCALATORS AND MOVING WALKS
(2) The plunger and the plunger (a) Materials. The cylinder and
connection to the car shall connecting couplings for the
also be so designed and cylinder shall be of materials with
constructed that the total a factor of safety of not less than
vertical deflection of the 5 based on the ultimate strength
loading edge of the car and with an elongation of not less
platform due to eccentric than 10% in 51 mm.
loading of the car shall not
exceed 19 mm. (b) Clearance at Bottom of
Cylinder. Clearance shall be
(b) Plunger Joints. Plungers provided at the bottom of the
composed of more than one cylinder so that the bottom of the
section shall have joints designed plunger will not strike the safety
and constructed to: bulkhead of the cylinder when the
car is resting on its fully
(1) carry in tension the weight of compressed buffer.
all plunger sections below the
joint with a factor of safety of (c) Cylinder and Plunger Heads.
not less than 4; and Heads of cylinders, and heads of
plungers subject to fluid pressure,
(2) transmit in compression the shall conform to the following
gross load on the plunger with requirements:
a factor of safety of not less
than 5 based on ultimate (1) Cylinder Heads. Bottom
strength. heads of cylinders only shall
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CHAPTER 6- ELEVATORS, DUMBWAITERS, ESCALATORS AND MOVING WALK
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6.5.7.4 Wall Thickness. The minimum wall (4) Control Means Affected.
thickness shall conform to the
following requirements: (a) Direct Plunger
(Maintained Pressure
(a) For working pressure up to 1,72 Type). The emergency
MPa, piping equal to standard terminal and normal
schedule 40 steel pipe may be terminal stopping
used without stress analysis. devices shall not control
the same controller
6.5.7.5 Threading. Pipe lighter than switches to complete the
Schedule 40 shall not be threaded. circuit to the control
valves unless two or
6.5.7.6 Supply Line Shut-Off Valve. A more separate and
manual shut-off valve shall be independent switches
installed in the supply line to the are provided, two of
cylinder of every hydraulic elevator which shall be closed in
where the cylinder is not exposed to the appropriate direction
inspection. The shut-off valve shall be of travel.
located in the machine room.
(b) Electro-Hydraulic. For
6.5.7.7 Emergency Terminal Speed the up direction of travel
Limiting Devices. at least two control
means are required, one
(a) Where Required. Emergency or both to be controlled
terminal speed limiting devices by the emergency speed
shall be installed where a limiting device and the
reduced stroke buffer is used and other or both by the
for the up direction where the car normal terminal stopping
speed exceeds 0.51 m/s to insure device. If, in the up
that the plunger does not strike its direction, the pump
solid limit of travel at a speed in motor is the only control
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CHAPTER 6- ELEVATORS, DUMBWAITERS, ESCALATORS AND MOVING WALKS
means, two magnetic range of the free suspension of the car and
switches, both of which not exceeding 76 mm.
shall be closed to
complete the motor b. The enclosure may be omitted on the upper
circuit, are required to landing on continuous pressure operation
satisfy this rule. If, elevators serving only adjacent landings
however, the pump (one floor travel) provided the floor opening
motor is one control at the upper landing is protected by an
means and there is a enclosure and gate at least 914 mm high
second control means, with openings that will reject a ball 25 mm in
(e.g., a valve) only one diameter and the gate is provided with a
magnetic switch for the combination mechanical lock and electric
pump motor is required. contact.
For the down direction,
the emergency terminal c. The enclosure may be omitted on the upper
speed limiting and landing of elevators having continuous
normal terminal stopping pressure operation and serving only
devices shall each adjacent landings (one floor travel), where
directly or through the floor opening is provided with a vertically
separate switches affect lifting hatch cover which is automatically
the control valve. Where raised and lowered vertically by he
two magnetic switches ascending and descending car, provided
are used, the emergency this cover meets the following requirements:
terminal speed limiting
and normal terminal 1. It is fitted with guides to insure its
stopping devices each proper setting.
may control one or both.
2. It is designed and installed to
6.5.7.8 Final Terminal Stopping Devices. Final sustain a total load of 3.59 kPa or
terminal stopping devices are not required. 136 kg at any one point.
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CHAPTER 6- ELEVATORS, DUMBWAITERS, ESCALATORS AND MOVING WALKS
storage purposes and shall be maintained sides and on the top. The enclosures shall
free of an accumulation of water. be constructed of solid or of openwork
material which will reject a bell 12.70 mm in
b. Pit Guard. A pit provided in other than a diameter.
hoistway that is enclosed for its full travel of
the car shall be guarded by a railing at least b. Securing Enclosures. Car enclosures shall
914 mm high and the entrance shall be be secured in conformance with the
provided with a door or gate. requirements of Sec. 6.4.5.2 and 6.4.5.3.
6.1.3 Top Car Clearance. The top car clearance c. Glass in Elevator Cars. Glass, where used
shall be not less than 152 mm plus 25 mm for in elevator cars, shall conform to the
each 0.07 m/s of the rated speed in excess of requirements of Sec. 6.4.5.7.
0.15 m/s.
6.2.3 Car Doors and Gates. A car door or gate
6.1.4 Between Car and Hoistway Enclosures or which, when closed, will guard the opening to
Counterweight. There shall be a clearance of a height of at least 1680 mm shall be provided
not less than 19 mm between the car and the at each entrance to the car. Car doors may
hoistway enclosure, and between the car and be of solid or openwork construction which will
its counterweight. reject a ball 76 mm in diameter.
6.1.5 Between Car and Landing Sill. The Collapsible car gates shall be of a design that,
clearance between the car platform and the when fully closed (extended position), will
landing sill shall be not less than 13 mm nor reject a ball 76 mm in diameter.
more than 38 mm.
a. Car Door or Gate Locking Devices.
6.1.6 Guarding of Suspension Means Where the hoistway enclosure is not
continuous for the full travel of the car, the
a. Suspension Means Passing Through car door or gate shall be provided with a
Floors or Stairs. Ropes and chains mechanical lock that will lock the car door or
passing through a floor or stairway outside gate if the car is more than 152 mm away
the hoistway enclosure shall be enclosed from a landing.
with a solid or openwork enclosure. If or
openwork, the enclosure shall reject a ball b. Car Door or Gate Electric Contacts.
12.70 mm in diameter. Means for inspection Every car door or gate shall be provided
shall be provided. The floor openings shall with an electric contact.
not be larger than is necessary to clear the
suspension means. The design of the car door or gate electric
contacts shall be such that for a sliding door
6.2 Cars or gate, the car cannot move unless the
door or gate is within 51 mm of the closed
6.2.1 Car Frames and Platforms. Materials used position. If the door or gate swings outward
in construction of car enclosures, frames, and to open, the car door or gate must be closed
platforms shall conform to the following: and locked before the car can move.
a. Cars shall have a metal or combination of 6.2.4 Light in Car. The car shall be provided with
metal and wood car frames and platforms an electric light. The control switch for the
having a factor or safety of not less than 5 light shall be located in the car and near the
based on rated load. car entrance. The minimum illumination at the
car threshold, with the door closed, shall be
b. Cast iron shall not be used in any member not less than 54 lx.
of the car frame or platform other than for
guides or guide shoe brackets. 6.3 Safeties and Governors
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CHAPTER 6- ELEVATORS, DUMBWAITERS, ESCALATORS AND MOVING WALKS
shall be provided with a safety conforming to 6.5.4 Replacement of Chains and Sprockets. If
the requirements of Section 6.63.2. chains are used as a suspension means and a
worm chain is replaced, all chains must be
6.3.2 Operation of Safeties. The car safety shall replaced. If a chain sprocket is replaced due
be of the inertia or other approved type to wear, all sprockets must be replaced.
operated by the breakage of the suspension
means or by the action of a speed governor. Section 7.0 Hand and Power
If of the speed governor type, the governor Dumbwaiters
shall operate the safety at a maximum speed
of 0.38 mis. On the breakage of the 7.1 Hoistways, Hoistway Enclosures, and
suspension means, the safety shall operate Related Construction
without delay and independently of the speed
governor action. 7.1.1 Applicable Requirements. Hoistways,
hoistway enclosures, and related construction
6.4 Limitation of Load, Speed, and Rise shall conform to the requirements of Article
6.3 except for the following Sections which do
6.4.1 Capacity. The rated load shall not exceed 318 not apply:
kg and maximum inside net platform area
shall not exceed 1.1 m . the minimum rated
2 Sec. 6.3.1.1(d) Strength of Enclosure
load shall be not less than that based on 1.91
kPa of inside net platform area of 159 kg Sec. 6.3.1.2 Floor Over Hoistways
whichever is greater.
Sec. 6.3.2.1 (a) Enclosures Required
6.4.2 Speed. The rated speed shall not exceed 0.20 for Elevators Having
m/s. Fire-Resistive
Hoistway Enclo-sures
6.4.3 Rise. The rise shall not exceed 15 m.
Sec. 6.3.2.2 Equipment in
6.5 Suspension Means Machine Rooms
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CHAPTER 6- ELEVATORS, DUMBWAITERS, ESCALATORS AND MOVING WALKS
enclosure at the top or bottom without conspicuously displayed on the landing side in
intervening enclosures or platforms. letters not less than 51 mm high, the words:
Power dumbwaiter machines and control “DANGER-DUMBWAITERS-KEEP CLOSED.”
equipment located outside the hoistway shall
be enclosed as required for electric elevators 7.1.7 Size and Location of Hoistway-Door
by Sec. 6.3.2.1 (a) except that control Openings
equipment located outside the hoistway may
be enclosed in a metal cabinet equipped to a. For Power Dumbwaiters. The size and
prevent access by unauthorized persons. location of openings shall conform to the
following:
7.1.3 Pits. Pits are not required.
1. Size of Openings. The width and
7.1.4 Types of Entrances height of openings shall not exceed
the width and height of the car by
a. For Power Dumbwaiters. Entrances shall more than 25 mm in each
be one of the following types: dimension.
7.1.6 Signs on Hoistway Doors of Hand 7.1.8 Rails for Entrances, Vertical Slide Type.
Dumbwaiters. Every hoistway door shall have The panel guide rails shall conform to the
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CHAPTER 6- ELEVATORS, DUMBWAITERS, ESCALATORS AND MOVING WALKS
requirements of Sec. 6.3.9.1 (c), except that machines and their control equipment located
they may be fastened only to the entrance inside the hoistway enclosure. Access
frame. openings shall:
7.1.9 Overlap of Entrance Panels for Entrances, (a) be of adequate size and so located as to
Vertical Slide Type. The entrance panels permit required maintenance and inspection;
with their attachments shall overlap the
entrance frame and sill by not less than 12.7 (b) have a maximum width of 610 mm and
mm. maximum height of 610 mm.
7.1.10 Hoistway-Door Locking Devices (c) be provided with doors which shall be kept
closed and locked.
a. For Power Dumbwaiters
7.2 Cars
At landings where the bottom of the
door opening 610 mm or more 7.2.1 Construction of Cars. Cars shall conform to
above the floor, the hoistway doors the following requirements:
shall be provided with hoistway-unit
system hoist-way door combination a. They shall be of solid openwork
mechanical locks and electric construction, and of such strength and
contacts. stiffness that they will not deform
appreciably when the load leans or falls
2. At landings where the bottom of the against the sides of the cars.
door opening is less than 610 mm
above the floor, the hoistway doors b. Non-metal cars sections shall be reinforced
shall be provided with hoistway-unit with metal from the bottom of the car to the
system hoistway door interlocks. point of suspension.
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CHAPTER 6- ELEVATORS, DUMBWAITERS, ESCALATORS AND MOVING WALKS
a. Maximum Rated Load. The 7.5.3 Belt-Drive Machine. Belts used as the
rated load shall not exceed 1,000 driving means between the motor and the
kilograms. machine of power dumbwaiters shall conform
to the following requirements:
b. Maximum Inside Net Platform
Area. The inside net platform a. Where flat belts are used, the rated speed
area shall not exceed 1.00 square shall be not more than 0.25 m/s.
meters.
b. Where multiple V-belts are used, the rated
7.3.2 Capacity Plate. A metalplate shall be speed shall be not more than 0.76 rn/s.
fastened in a conspicuous place in the car and
shall indicate the rated load in letters and 7.5.4 Driving-Machine Brakes. Electric and hand
numerals not less than 6.3 mm high, stamped, driving machines shall be equipped with
etched, or raised on the surface of the plate. brakes as follows:
7.4 Car and Counterweight Safeties a. Electric driving machines shall have
electrically released brakes applied
7.4.1 Where Required. Car and counterweight automatically by springs in compression or
safeties shall not be required except for by gravity when power is removed from the
protection of spaces below hoistway for all motor.
dumbwaiter cars and counterweights having a
rated load over 11.3 kg. Where required, the b. Hand driving machines shall be equipped
car and counterweight safeties may be with handbrakes or automatic brakes which
operated as a result of breaking the will sustain the car and its rated load. When
suspension means and may be of the inertia the brake is applied, it shall remain locked in
type without governors. Car safeties may be the “On” position until released by the
located in the car crosshead. operator.
7.5 Driving Machines and Sheaves Exception Sec. 6.7.5.4 (b): For rated loads
of 9.1 kg or less, the brake may be omitted
7.5.1 Types of Power Driving Machines provided the machine has sufficient friction
Permitted. Driving machines shall be one of to hold the car and its rated load at any
the following types: floor.
f. Belt-Drive — Single Belt 7.6 Car and Counterweight Guides and Guide
Fastenings
g. Chain-Drive
7.6.1 Guides for Dumbwaiters Having a Capacity
h. Roped-Hydraulic of more than 9.1 kg. Car and counterweight
guides shall be of metal, wood, or wood and
7.5.2 Factor of Safety of Driving Machines and metal bolted together.
Sheaves. Driving machines and sheaves
shall be designed with a factor of safety, 7.6.2 Guides for Dumbwaiters Having a Capacity
based on the static load (the rated load plus of 9.1 kg or less. Car and counterweight
the weight of the car, ropes, counterweights, guides shall be of metal, wood and metal
etc.) of not less than 6 for steels, and 9 for bolted together, metal tubes, or spring steel
cast iron and other materials. wires maintained in tension.
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CHAPTER 6- ELEVATORS, DUMBWAITERS, ESCALATORS AND MOVING WALKS
7.6.3 Use of the Set of Guides for Car and b. Rated Loads of 34.0 kg or less.
Counterweight. The same set of guides may Dumbwaiters having a rated load of 34.0 or
be used for both the car and counterweight. less may be suspended by manila or
braided-cotton ropes having a factor of
7.6.4 Guide Fastenings and Joints. Guides shall safety of not less than 6.
be securely fastened to the hoistway.
Section 8.0 Escalators
Guide joints shall be either tongue and groove
or doweled and fitted and splice plates. 8.1 Protection of Floor Openings
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CHAPTER 6 - ELEVATORS, DUMBWAITERS, ESCALATORS AND MOVING WALKS
beveled unless parallel to the direction of provided they meet the requirements of Sec.
travel. 6.8.3.2 (b).
Balustrades shall be designed to resist the Exception Sec. 6.8.3.2 (e): Where the
simultaneous application of a lateral force of clearance of the upper outside edge of the
584 N/m and vertical load 730 N/rn, both balustrade and the ceiling or soffit is more
applied to the top of the balustrade. than 305 mm or where the intersection of
the outside balustrade and the ceiling or
The skirt panel adjacent to the step shall be soffit is more than 610 mm from the
constructed of material having a smooth centerline of the handrail.
surface. Embossed, perforated, or roughly
textured materials shall not be used. f. Anti-Slide Device. Anti-slide devices shall
be provided on decks or corn binations of
Skirt panels shall not deflect more than 1.6 decks when the outer edge of the deck is
mm under a force of 68 kg applied to any greater than 305 mm from the centerline of
exposed point between the upper and lower the handrail or, on adjacent escalators,
combplates. when the distance between the handrails is
greater than 406 mm.
b. Use of Glass or Plastics in Balustrades.
Glass or plastics, if used in balustrades, These devices shall consist of raised objects
shall conform to the requirements of ANSI fastened to the decks, no closer than 102
Z97.1, except that there shall be no mm to the handrail, and spaced no greater
requirement for the panel to be transparent. than 183 mm, apart. The height shall be not
less than 19 mm. They shall have no sharp
Exception Sec. 6.8.3.2 (b): Plastics corners or edges.
bounded to a basic supporting panel.
8.3.3 Handrail
c. Clearance Between Balustrades and
Steps. The clearance on either side of the a. Type Required. Each balustrade shall be
steps between the step tread and the provided with a handrail moving in the same
adjacent skirt panel shall not be more than direction and at substantially the same
4.8 mm. speed as the steps.
In charging from the greater to the smaller c. Guards. Hand or finger guards shall be
width, the maximum allowable angle of provided at the point where the handrail
change in the balustrade shall be 15 deg. enters the balustrade.
from the line of travel.
d. Distance Between Handrails. The
e. Guards at Intersections. A solid guard horizontal distance between the centerlines
shall be provided in the intersection of the of the two handrails, measured on the
angle of the outside balustrade (deck board) incline, shall not exceed the width between
and the ceiling of soffit. the balustrades (See Sec. 6.8.3.1) by more
than 152 mm, with a maximum of 76 mm on
The vertical front edge of the guard shall either side of the escalator (see Appendix F,
project at least 356 mm horizontally from the Fig. Fl).
apex of the angle. The escalator side of the
vertical face of the guard shall be flush with 8.3.4 Steps
the face of the well way.
a. Material and Type. Step frames shall be
The exposed edge of the guard shall be made of non-combustible material.
rounded. Guards may be of glass or plastic
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Steps treads shall be horizontal and made Where tightening devices are operated by
of non-combustible material which will afford means of tension weights, provision shall be
a secure foothold. made to retain the weights in the truss if they
should be released.
Exception: Step tread material may be slow
burning type if covered on the underside 8.3.7 Step Wheel Tracks. Step wheel tracks shall
with sheet metal not less than 0.44 mm thick be designed so as to prevent displacement of
or with equivalent fire-resistive material. the steps and running gear if a step chain
breaks.
b. Dimensions of Steps. The depth of any
step tread in the direction of travel shall be 8.3.8 Rated Load
not less than 400 mm, and the rise between
treads shall be not more than 216 mm. The a. Structural. For the purposes of structural
width of a step tread shall be not less than design, the rated load in kilograms shall be
406 mm nor more than 1016 mm. (See considered to be not less than:
Appendix F, Fig. Fl)
Structural rated load = 4.6 WA
c. Slotting of Step Risers. The step riser shall
be provided with vertical cleats which shall where:
mesh with slots on the adjacent step tread
as the steps made the transition form incline A = length of the horizontal projection of
to horizontal. the entire truss, mm
d. Slotting of Step Treads. The tread surface W = width of the escalator, mm.
of each step shall be slotted in a direction (see Sec. 6.8.3.1)
parallel to the travel of the steps. Each slot
shall be not more than 6.3 mm wide and not b. Machinery. For the purpose of driving
less than 9.5 mm deep; and the distance machine and power transmission
from center to center of adjoining slots shall calculations, the rated load in kilograms
be not more than 9.5 mm. shall be considered to be not less than:
Slots shall be so located on the step tread Machinery rated load = 3.5 WB where:
surface as to form a cleat on each side of
the step tread adjacent to the skirt panel. B = 1.32 x rise, meter
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f. Broken Drive-Chain Device. When the in the passenger carrying line of the track
driving machine is connected to the main system.
drive shaft by a chain, a device shall be
provided which will cause the application of m. Tandem Operation. Tandem operation
the brake on the main drive shaft and also escalators shall be electrically interlocked
stop the drive machine if the drive chain where traffic flow is such that bunching will
parts. occur if the intermediate landing stops.
g. Stop Switch in Machinery Spaces. A stop The interlocks shall stop the escalator
switch, conforming to the requirements of carrying passengers into the common
Sec. 6.4.11.3 (e), shall be provided in each intermediate landing if the escalator carrying
machinery space where means of access to passengers away from the landing stops.
the space is provided. This switch, when These escalators shall also be electrically
opened, shall cause the electric power to be interlocked to assure that they run in the
removed from the escalator driving machine same direction.
motor and brake.
8.5.5 Signs. A caution sign shall be located at the
Exception [Sec. 6.8.5.4 (g)J: Machinery top and bottom landing of each escalator,
spaces in which main line disconnect switch readily visible to the boarding passengers.
is located. The sign shall include the following wording:
Rolling Shutter Device. Rolling shutters, if The sign shall be standard for all escalators
used, shall be provided with a device which and shall be identical in format, size, color,
shall be actuated as the shutter begin to wording and pictorials as shown in Fig. F2
close to cause the opening of the power Appendix F.
circuit to the escalator driving machine
motor and brake. The sign shall be durable and have a
maximum thickness of 6.5 mm with rounded
j. Reversal Stop Device. Means shall be or beveled corners and edges.
provided to cause the opening of the power
circuit to the driving-machine motor and 8.5.6 Access to Interior. Reasonable access to
brake in case of accidental reversal of travel the interior of the escalator shall be provided
while the escalator is operating in the for inspection and maintenance.
ascending direction.
Section 9.0 Moving Walks
k. Step Demarcation Lights. Green step
demarcation lights located below the step 9.1 Design Requirements
shall be located at both landing in an area
not to exceed 406 mm from combplate. 9.1.1 Direction of Passage. Passage from a
There shall be a minimum of two fluorescent landing to a treadway or vice versa shall be in
lamp fixtures at each landing. The lamps the direction of treadway travel at the point of
shall be activated whenever the escalator is passenger entrance or exit.
in operation.
9.1.2 Load Rating
Step Upthrust Device. Means shall be
provided to cause the opening of the power a. Structural. For the purpose of structural
circuit to the escalator driving machine design, the load rating shall be considered
motor and brake should a step be displaced to be not less than 4.78 kPa of exposed
against the upthrust tract at the lower curve treadway.
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b. Machinery. For the purpose of brake c. Grooving. The treadway surface shall be
treadway, and power transmission grooved in a direction parallel to its travel for
calculations, the load rating shall be the purpose of meshing with combplates at
considered to be not less than 3.69 kPa of the landings. Each groove shall be not
exposed treadway. more than 6.3 mm wide at the treadway
surface and not less than 4.8 mm deep; and
9.1.3 Width the distance from center to center of
adjoining grooves shall be not more than 13
a. Limitations. The width of moving walk (the mm. Sides of grooves may slope for mold
exposed width of treadway) shall be not less draft purposes and may be filleted at the
than 560 mm. The maximum width shall bottom.
depend both on the maximum treadway
slope at any point on the treadway, and on 9.1.5 Belt Pallet Type Treadway. Belt pallet type
the treadway speed. The width shall not treadways shall conform to the following:
exceed the value shown in Table 6.9.1.3 (a).
a. Factor of Safety. Pallet connecting chains
b. Change in Width. The exposed width of or other connecting devices between pallets,
treadway shall not be decreased in the and. pallets where part of the propelling
direction of travel. system, shall have a factor of safety of not
less than 10 based on ultimate strength.
This width requirement applied only to
moving walks having entrance to or exit b. Splices. Splicing of the treadway belt shall
from landings. It is not intended to preclude be made in such a manner as to result in a
development of moving walk systems in continuous unbroken treadway surface of
which changes in width are made safe and the same characteristics as the balance of
practical by direct passage from one the belt.
treadway to another, subject passage from
one treadway to another, subject to the c. Grooving. The treadway surface shall be
approval of the enforcing authority. grooved in direction parallel to its travel for
the purpose of meshing with combplates at
Table 6.9.1.3 (a) the landings. Each groove shall not be more
Treadway Width than 4.8 mm deep; and the distance from
center to center of adjoining grooves shall
Maximum Movinq Walk Treadway Width, in be not more than 12.70 mm slides of
Max. 90 fpm Above 90 Above 140 grooves may slope for mold draft purposes
Treadway Max. fpm to 140 fpm to 180 and may be filleted at the bottom.
Slope at any Treadway tpm fpm
point, deg Speed Treadway Treadway
Speed
d. Alignment. Adjacent ends of pallets shall
Speed
0 to 4 Unrestricted not vary in elevation more than 1.6 mm. The
60 40
Above 4 to 8 40 40 40 fasteners that attach the belt to the pallets
Above 8 to 12 40 40 Not shall not project above the exposed
permitted treadway surface.
9.1.4 Belt Type Treadway. Belt type treadways 9.1.6 Pallet Type Treadway. Pallet type treadways
shall conform to the following: shall conform to the following:
a. Factor of Safety. Belt type treading shall a. Factor of Safety. Pallet connecting chains
be designed with a factor of safety of not or other connecting devices between pallets,
less than 5 based on ultimate strength. and pallets where part of the propelling
system, shall have a factor of safety of not
b. Splices. Splicing of the treadway belt shall less than 10 based on ultimate strength.
be made in such a manner as to result in a
continuous unbroken treadway surface of b. Grooving. The treadway surface of each
the same characteristics as the balance of pallet shall be grooved in a direction parallel
the belt. to its travel. Each groove shall be not more
than 6.3 mm wide at the treadway surface
and not less than 4.8 mm deep; and the
125
_______
distance from center to center of adjoining the slider bed shall be reasonably smooth.
grooves shall be not more than 13 mm. It shall be so constructed and it will not
Sides of the grooves may slope for mold support combustion.
draft purposes and may be filleted the
bottom. b. Roller Bed. Where the treadway is
supported on a series of rollers, the
c. Intermeshing Pellets. Alternate cleats on combination of roller spacing, belt tension,
adjacent pallets hsall intermesh so that and belt stiffness shall be such that the
there is no continuous transverse gap deflection of the treadway surface, midway
between adjacent pallets. between roller, shall not exceed the quantity
0.239 mm plus 0.004 times the center to
d. Alignment of Pallet Tread Surfaces. center distance of rollers in millimeter when
Adjacent ends of pallets shall not vary in measures as follows:
elevation more than 1.6 mm.
The treadway surface shall be loaded
9.1.7 Treadway Slope. The slope of the treadway midway between rollers with a 11.3 kg
shall not exceed 3 degrees within 914 mm of weight concentrated on a cylindrical
the entrance and exit and shall not exceed 12 footpiece 51 mm long by 25 mm in diameter
degrees at any point. placed with its long axis across the belt.
Deflection of this footpiece from its unloaded
9.1.8 Speed. Treadway speed shall conform to the position shall not exceed the figure obtained
following: above.
a. Maximum Speed. The maximum speed of The rollers shall be conventric and true
a treadway shall depend on the maximum running within commercially acceptable
slope at any point on the treadway. This tolerances.
speed shall not exceed the value
determined by Table 6.9.1.8 (a).
c. Edge Supported Belt. When the treadway
b. Higher Speeds. The maximum speeds belt is transversely rigid and is supported by
listed in Table 6.9.1.8 (a) apply only to rollers along its edges, the following
moving walks having an entrance or exit to requirements shall apply:
landings. It is not intended to preclude
development of moving walk systems in 1. With the belt tensioned through the
which higher speeds are made safe take-up system, the permissible
practical, subject to the approval of the slope of a straight line from the top
enforcing authority. of a treadway rib adjacent to the
balustrade, in a plane perpendicular
Table 6.9.1.8 (a) to the path of the treadway shall not
Tread Speed exceed 3% when the treadway is
loaded with a 68 kg weight on a 152
Maximum Treadway Slope Maximum Treadway mm by 254 mm plate located on the
At any Point onTreadway, deg. Speed, fpm centerline of the treadway with 254
0 to 8 180
mm dimension in the direction of
Above 8 to 12 140 treadway travel.
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CHAPTER 6- ELEVATORS, DUMBWAITERS, ESCALATORS AND MOVING WALKS
d. Pallet and Belt Pallet Type. Pallet wheel 3. Balustrades shall be designed to
tracks shall be so designed and located as resist the simultaneous application
to prevent more than 3.2 mm vertical of a lateral force of 584 N/m and a
displacement of the treadway should the vertical load of 730 N/rn ,both
pallet connection means break. applied to the top of the
balustrades.
9.1.10 Threshold Plates. The entrance to or exit
from a moving treadway shall be provided with b. Geometry. The height of the balustrade
a threshold plate designed and installed to shall be not less than 838 mm nor more
provide smooth passage between treadway than 1070 mm from the treadway to the top
and landing and vice versa and it shall of handrail, measured perpendicular to the
conform to the following: treadway surface. The handrail shall be a
minimum of 102 mm horizontally and 25 mm
a. Type Required. The threshold plate shall vertically away from adjacent surfaces. The
be provided with a comb. center line of the handrail shall be not more
than 254 mm, measured horizontally, from
b. Clearance. The threshold comb teeth shall the vertical plane through the edge of the
be meshed with a set into the grooves in exposed treadway (see Appendix F, Fig.
treadway surface so the points of the teeth F3).
are always below the upper surface of the
treadway. c. Clearance with Treadway. If the balustrade
covers the edge of the treadway, the
c. Surface. The suiface of the plate shall clearance between the top surface of the
afford a secure foothold. The surface shall treadway and the underside of the
be smooth from the point of intersection of balustrade shall not exceed 6.3 mm. Where
the comb teeth and upper surface of the skirt panels are used, the horizontal
treadway, for a distance not exceeding 102 clearance on either side of the treadway
mm and not less than 25 mm. between the treadway and the adjacent skirt
panel shall be not more than 6.3 mm.
9.1.11 Balustrades. Moving walks shall be provided
with an enclosed balustrade on each side 9.1.12 Guards at Ceiling Intersections.
conforming to the following:
a. A solid guard shall be provided in the
a. Construction intersecting angle of the outside balustrade
(deck board) and the ceiling or soffit.
1. Balustrades without moving
handrails shall be designed so as to Exceptions:
provide no surfaces which can be
gripped by a passenger. On the (1)Where the distance from the face of the
treadway side, the balustrade shall weliway to the centerline of the handrail
have no areas or moldings is more than 610 mm.
depressed or raised more than 6.3
mm from the parent surface. Such (2) Where the clearance between the face of
areas or moldings shall have all the well way and the upper outside edge
boundary surfaces beveled unless of the balustrade is more than 305 mm.
parallel to the direction of travel.
The balustrade shall extend at b. The horizontal length of the guard shall be
normal height not less than 305 mm such that the vertical edge of the guard shall
beyond the end of the exposed be at least 191 mm high. The moving walk
treadway. side of the vertical face of the guard shall be
flush with the face of the wellway. The
2. Glass or plastics panels, if used in exposed edge of the guard shall be
the balustrades shall conform to the rounded. Guards may be of glass or plastic
requirements of ANSI Z97.1, except provided they meet the requirements of
that there shall be no requirement Section 6.9.1.11 (a)(2).
for the panels to be transparent.
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CHAPTER 6- ELEVATORS, DUMBWAITERS, ESCALATORS AND MOVING WALKS
9.1.13 Handrails. Handrails shall conform to the gravity under any load condition up to and
following: including the rated load condition up to and
including the rated load with the power
a. Number Required. Two moving handrails supply interrupted do not require brakes.
shall be provided on each moving walk.
c. Application of Brakes. Electrically
Exception: A single moving handrail may be released brakes specified in Sc. 6.9.1.14 (b)
used for moving walks having a slope of 3 shall stop the treadway automatically upon
degrees or less, a speed of (0.36 mIs), or failure of power or when any of the safety
less and a width of 610 mm or less. devices specified in Section 6.9.2 operate.
Brakes on the main drive shaft, if not of the
b. Location. The moving handrail at both the electrically released type, shall be applied
entrance and exit landings shall extend at should the drive chain part.
normal height not less than 305 mm beyond
the end of the exposed treadway. The point d. Speed Reducers. Speed reducers shall
at which the moving handrail enters or meet the requirements for design and
leaves an enclosure shall be not more than application as established for various types
254 mm above the floor line. in the appropriate Gear Manufacturer’s
Practice Standards.
c. Handrail Guards. Hand or finger guards
shall be provided at the points where the The loading shall be considered to be
handrails enter the enclosures. uniform and the service to be 24 hours per
day.
d. Enclosure. The moving handrail return run
and its driving and supporting machinery e. Chain Drives. Chain drives shall be of the
shall be fully enclosed. types covered by ANSI B29.1 and
ANSI/SAE SP-68.
e. Speed. Each moving handrail shall move in
the same direction and at substantially the When operating at the load rating of the
same speed as the treadway. treadway, the load imposed on such chains
shall not exceed the horsepower rating as
9.1.14 Drive, Motor and Brake established by these standards.
Where a chain is used to connect the driving g. Other Components. Pallet propelling
machine to the main drive shaft, a brake chains and drive and breaking components
shall be provided on the main drive shaft. It other than those specified shall have a
is not required that this brake be of the factor of safety of not less than 10.
electrically-released type if an electrically-
released brake is provided on the driving
machine. 9.1.15 Supporting Structure. The supporting
structure for the treadway, balustrades, and
Exception [Sec. 6.9.1.14(b)]: Moving walks machinery shall conform to the requirements
which will not run in the down direction by of the AISC Specification for Design,
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CHAPTER 6- ELEVATORS, DUMBWAITERS, ESCALATORS AND MOVING WALKS
Fabrication and Erection of Structural Steel for where the brake is directly coupled to
Buildings. the driving machine and where a device
is provided that will cause interruption of
9.2 Operating and Safety Devices, Electrical power to the motor and apply the brake
Equipment and Wiring should the belts or chains lose tension
of brake.
9.2.1 Devices Required. Operating and safety
devices shall be provided conforming to the e. Broken Treadway Device for Belt Pallet
following requirements: Type and Pallet Type. A device shall be
provided which will cause interruption of
a. Starting Switch. Starting switches shall be power to the driving machine and to the
of the key-operated type and shall be brake, where provided, if the connecting
located upper or lower landing so that the means between pallets break.
exposed treadway is within sight.
f. Power Interruption. Where a device is
b. Emergency Stop Switches. Emergency required to interrupt power, such interruption
stop buttons or other types of manually shall not be subject to intentional delay. The
operated switches having red buttons or use of a supplemental and independent
handles shall be accessibly located at every device with or without intentional delay is
entrance to the exit from a moving walk, and permissible.
shall be protected against accidental
operation. The operation of any of these g. Stop Switch in Machinery Spaces. A stop
buttons or switches shall interrupt the power switch conforming to the requirements of
to the driving machine and to the brake, Sec. 6.4.11.3 (e) shall be provided in each
where provided. It shall be impossible to machinery space where means of access to
start the driving machine by these buttons or the space is provided. This switch, when
switches. opened, shall cause electrical power to be
removed from the driving machine motor
c. Broken Drive-Chain Switch. Where the and brake.
driving machine is connected to the main
drive shaft by a chain, and where a brake is Exception: Machinery space in which the
located on the main drive shaft when main line disconnect switch is located.
required by Sec. 6.9.1.14 (b), a device shall
be provided which will cause application of h. Rolling Shutter Device. Rolling shutters if
the brake should the drive chain part. used, shall be provided with a device which
shall be actuated as the shutters begin to
d. Speed Governor. Moving walks required close to cause the opening of the power
by Sec. 6.9.1.14 (b) to be equipped with a circuit to the moving walk driving machine
brake, or which are driven by a direct motor and brake.
current motor, shall be provided with a
speed governor which will cause the
interruption of power to the driving machine
and to the brake, where provided, should
the speed of the treadway exceed a pre
determined speed which shall be not more
than 40% above the maximum designed
treadway speed.
129
CHAPTER 7— BOILERS AND PRESSURE VESSELS
Chapter 7
Definitions:
Locomotive Boiler — a boiler mounted on a self-
Boiler or Steam Generator a closed vessel
— propelled track locomotive and used to furnish
intended for use in heating water or for application of motivating power for traveling on rails. (It does not
heat to generate steam or other vapor to be used include locomotive cranes, tractors, or other self-
externally to itself. propelled apparatus). Locomotive boilers however, if
dismantled from locomotive and reinstalled for
Coal-Fired Boiler used stokered water temperature
—
stationary use, are not included in this definition.
coal or pulverized coal for water-tube.
Low Pressure Heating Boiler a boiler operated at a
—
rejection by qualified inspecting authority. at pressure not exceeding 103.5 MPa gage steam, or
water temperature not exceeding 130°C.
Existing Installations any boiler or unfired pressure
—
vessel constructed, installed, placed in operation but Miniature Boiler as used in this Code herein mean
—
subject to periodic inspection. any boiler which does not exceed any of the following
limits: 405 mm inside diameter, 1065 mm overall
External Inspection an inspection made on the
—
2 of water
length of outside of heads at center, 1 .85m
external parts, accessories and/or component even 2 maximum allowable
heating surface, 7.03 kg/cm
when a boiler or unfired pressure vessel is in working pressure.
operation.
New Boiler or Unfired Pressure Vessel Installation
Fire Tube Boiler — a boiler where heat is applied — include all boilers and unfired pressure vessels
inside the tube. constructed, installed, placed in operation or
constructed for.
Fusion Welding — a process of welding metals in a
molten and vaporous state, without the application of Oil-Fired Boiler uses Bunker C as fuel for heating
—
mechanical pressure or blows. Such welding may be boiler and power boiler.
accomplished by the oxy-acetylene or hydrogen flame
or by electric arc. Thermal welding is also classified Portable Boiler an internally fired boiler which is
—
boiler or unfired pressure vessel is shut down and Boiler Construction Code, shall mean the Boiler
handholes, manholes, or other inspection openings Construction Code of the American Society of
Mechanical Engineers with amendments and
are opened or removed for inspection of the interior.
interpretations thereto made and approved by the
Council of the Society.
130
CHAPTER 7— BOILERS AND PRESSURE VESSELS
Reinstalled Boiler or Unfired Pressure Vessel a — permit and other permits necessary should
boiler or unfired pressure vessel removed from its also be stipulated on the plan.
original setting and re-erected at the same location or
erected at a location without change of ownership. b. Detailed assembly plan of boiler should
show all appendages indicating instruments,
Second Hand Boiler or Unfired Pressure Vessel — panels if any for controls and all safety
as used herein shall mean a boiler or unfired pressure devices. Details should show actual joints,
vessel of which both the location and ownership have riveting, welding, thickness of plates, tubes,
been changed after primary use. fusible plugs etc. Steam conditions like
temperature, pressure, degrees superheat
Steam System — comprises steam generation, should be indicated.
distribution, and utilization. It includes fuel, combustion
air, feedwater, combustion system, steam quality and c. Piping drawing, preferably in isometric
efficiency. drawing showing elevations headers, leads
to headers preferably from the bottom,
Unfired Pressure Vessel a vessel in which
— branches from headers, preferably from the
pressure is obtained from an external source, or from top, expansion joints, pipes covering sizes,
an indirect application of heat. fittings and valves and method support.
a. General Layout giving a plan view, a. Although not to be used for passage, boiler
longitudinal view and at least a front view rooms should be provided with two doors
showing location of boiler with respect to preferably on opposite ends or sides which if
building, location, size and height of smoke locked may be opened without key from the
stack, location of steam generator auxiliaries inside.
and location and size of fuel supply.
Building permit and location plan of the b. As the room air is usually the source of
same, Electrical permit, Fire Department combustion air, sufficient ventilation from
outside should be provided.
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CHAPTER 7— BOILERS AND PRESSURE VESSELS
a. Brickwork should be provided with sufficient d. Where two or more steam boilers will be
expansion joints both vertically and connected in parallel, each steam outlet
horizontally to take care of expansion at should be provided with a non-return valve
operating temperature. and a shut off valve.
b. Insulating castables is used for medium e. Only steam pressure sufficient for
pressure boiler. requirements should be allowed. No high
pressure will be generated just to be
1.5 No structural stress other than its own weight reduced on the line to suit requirements.
should be imposed on any brickwork and in no
case should the full weight or part weight of f. All construction features of boiler should be
steam boiler or its appurtenances be supported in conformity with the ASME Boiler
on brickwork. Construction Code when available or its
equivalent. (JIS, ASTM, ISO Standards).
1.6 No steam boiler should be enclosed or walled-in
without authorization and inspection by g. All boiler installations, including reinstalled
authorized government representative and who boilers, shall be installed in accordance with
will conduct a hydrostatic test of 130% of the requirements of the latest revision of the
stipulated working pressure. A.S.M.E. Boiler Construction Code and/or
Rules and Regulations provided herein.
1.7 Ceiling Clearance
h. Ladders and Catwalks. A steel catwalk or
a. When boilers are replaced or new boilers platform at least 455 mm wide and provided
are installed in either existing or new with standard handrails and toe-board on
buildings, a minimum height of at lest 2,130 either side shall be installed across the tops
mm shall be provided between the top of the of adjacent boilers or at some other
boiler proper and the ceiling except in single convenient level for the purpose of affording
installation of self-contained boilers where a safe access to the boilers. All catwalks shall
minimum height of at least 915 mm shall be have at least two means of exit, each exit to
provided between the highest point of any be remotely located from the other, and
valve stem or fitting and the ceiling. connected to a permanent stairway or
inclined ladder leading to the floor level.
1.8 Other Requirements
Section 2.0 Specific Requirements for
a. All boilers and unfired pressure vessels shall Fired Tube Boilers
be so located that adequate space will be
provided for the proper operation of the 2.1 Maximum Allowable Working Pressure. The
boiler and its appurtenances, for the maximum allowable working pressure on the
inspection of all surfaces, tubes, water walls, shell of a boiler or drum shall be determined by
economizers, piping, valves and other the strength of the weakest SECTION OF THE
equipment and for their necessary STRUCTURE, computed from the thickness of
maintenance and repair. the plate, the tensile strength of the plate, the
efficiency of the longitudinal joint, OR TUBE
b. Smokestacks should be of sufficient LIGAMENTS, the inside diameter of the outside
capacity to handle flue gases, self- course and the factor of safety by these rules.
132
CHAPTER 7- BOILERS AND PRESSURE VESSELS
The resistance to crushing of mild steel shall 1. The use of weighted-lever safety
be taken at 655.17 N/mm of cross sectional valves shall be prohibited and direct
area. spring-loaded pop type valves shall
replace these valves.
2.3 Factor of Safety
2. Safety valves having either the seat
a. The Professional Mechanical Engineer shall or disc of cast iron shall not be
increase the following factors of safety shall used.
be increased if the condition and safety of
the boilers demand it. 3. Each boiler shall have at least one
safety valve and if it has more than
b. The lowest factor of safety permissible on 2 of water heating surface or
46.5 m
existing installations shall be 4.5 except for the generating capacity exceeds
horizontal return tubular boilers having 910 kg/hr, it shall have two (2) or
continuous lap seams more than 3,650 mm more safety valves.
in length where the factor of safety shall be
9, and when this latter type of boiler is
133
CHAPTER 7— BOILERS AND PRESSURE VESSELS
134
CHAPTER 7— BOILERS AND PRESSURE VESSELS
b. A boiler having more than 46.5 m 2 of water steam connection to the water column. The
heating surface shall have at least two steam gage shall be connected to a siphon
means of feeding, one of which shall be an or equivalent device of sufficient capacity to
approved feed pump or injector. Where a keep the gage tube filled with water and so
source of feed directly from pressure mains arranged that the gage cannot be shut off
is available at sufficient pressure to feed the from the boiler except by a cock placed near
boiler against a pressure 6 percent greater the gage and provided with a tee or level
than the release pressure of the safety valve handle arranged to be parallel to the pipe in
with the highest release setting, this may be which it is located when the cock is open.
considered one of the means.
d. When a steam gage connection longer than
c. The feed piping to the boiler shall be 2,440 mm becomes necessary, a shut off
provided with two check valves near the valve may be used provided the boiler is of
boiler and a valve near the pump. When the outside screw and yoke type and is
two or more boilers are fed from a common locked open. The line shall be ample size
source, there shall also be a valve on the with provision for free blowing.
branch to each boiler between the check
vale and the boiler. When two or more e. Each boiler shall be provided with a 6.35
boilers are fed from a common source, there mm nipple and globe valve connected to the
shall also be a valve on the branch to each steam space for the exclusive purpose of
boiler between the check valve and source attaching a test gage when the boiler is in
supply. Whenever a globe valve is used on service so that the accuracy of the boiler
feed piping, the inlet shall be under the disc steam gage may be ascertained.
of the valve.
f. Each stem outlet from a boiler (except
d. Where deaerating heaters are not safety valve connections) shall be fitted with
employed, it is recommended that the a stop valve located as close as practicable
temperature of the feedwater be not less to the boiler.
than 102°C to avoid the possibility of setting
up localized stress. Where deaerating g. When a stop valve is so located that water
heaters are employed, it is recommended can accumulate, ample drains shall be
that the minimum feedwater temperature be provided. The drainage shall be piped to a
not less than 197°C so that dissolved gases safe location and shall not be discharged on
may be thoroughly released. the top of the boiler or its setting.
2.6 Gages and Gage Connections — Fire Tube h. When boilers provided with manholes are
Boilers connected to a common steam line, the
steam connection from each boiler shall be
a. Each boiler shall have three or more gage fitted with two stop valves having an ample
cocks, located within the range of the visible free flow drain between them. The
length of the water glass, except when such discharge of this drain shall be visible to the
boiler has two water glasses with operator while manipulating the valves and
independent connections to the boiler, shall be piped clear of the boiler setting.
located on the same horizontal line and not The stop valves shall consist preferably of
less than 610 mm apart. one automatic non-return valve and a
second valve of the outside-screw and yoke
b. For all installations where the water gage type.
glass or glasses are more than 9,000 mm
from the boiler operating floor, it is 2.7 Blow Off Connections — Fire Tube Boiler
recommended that water level indicating or
recording gages be installed at eye height a. The construction of the setting around each
from the operating floor. blow-off pipe shall permit of free expansion
c. Each steam boiler shall have steam gage, and contraction. Careful attention shall be
with dial range not less than one and one- given to the problem of sealing these setting
half (11/2) times and not more than twice the openings without restricting the movement
maximum allowable working pressure, of the blow-off piping.
connected to the steam space or to the
135
CHAPTER 7— BOILERS AND PRESSURE VESSELS
g. All cases not specifically covered by these 2. In those cases where the boiler is
rules and regulations shall be treated as supplied with feedwater directly
New Installations or may be referred to the from a pressure main or system
government agency for instructions without the use of a mechanical
concerning the requirements . feeding device, the safety valve
shall be set to release at a pressure
not in excess of ninety-four (94)
Section 3.0 Specific Requirements for
percent of the lowest pressure
Miniature Boilers obtained in the supply main or
system feeding the boiler. Return
3.1 New Boiler Installations traps shall not be considered
mechanical feeding devices.
a. No Miniature Boiler, except reinstalled
boilers and those exempted by these Rules d. Water Gage Glass
and Regulations, shall hereafter be installed
unless it has been constructed! inspected 1. Each miniature boiler shall be
and stamped in conformity with ASME Boiler equipped with water gage glass for
Construction Code and is approved, the determination of water level.
registered and inspected in accordance with
these Rules and Regulations.
136
CHAPTER 7— BOILERS AND PRESSURE VESSELS
2. The lowest permissible water level where the boiler is operated without
shall be at a point one-third (1/3) of extraction of steam (closed system).
the height of the shell, except where
the boiler is equipped with internal 4. Feedwater shall not be introduced
furnace, in which case it shall be not through the water column or gage
less than one-third of the tube glass connections while the boiler is
length above the top of the furnace. under pressure.
a) Where the boiler is connected to Each miniature boiler shall be equipped with
a water main or system having a steam gage having a dial range not less
sufficient pressure to feed the than one and one-half (11/2) times and not
boiler at any time while under more than twice the maximum allowable
pressure. working pressure. The gage shall be
connected to the steam space or to the
b) Where the fuel burned is such steam connection to the gage glass by a
that all heat input can be brass or bronze composition siphon tube, or
discontinued instantaneously by equivalent device that will keep the gage
the operation of a valve, cock, tube filled with water.
or switch, thereby permitting the
boiler pressure to be quickly h. The steam piping from a miniature shall be
lowered to a point where water provided with a stop valve located as close
can be introduced from the to the boiler shell or drum as is practicable,
connection to the water main. except in those cases where the boiler and
steam receiver are operated as closed
c) Where the boiler is operated system.
without extraction of steam
(closed system) in which case For installations which are gas-fired, the
the boiler is filled, when cold, burners used shall conform to the
through the connections or requirements of the American Gas
opening provided in accordance Association, as stated in the ASME Boiler
with the following rule. Construction Code.
2. Each miniature boiler shall be fitted j. Each gas-fired boiler shall be equipped with
with a feedwater connection which a 100 mm vent pipe or flue extended to an
shall not be less than 12.7 mm iron approved location outside the building or
pipe size. The feed piping shall be connected to a chimney flue. Where the
provided with a check valve near horizontal run is more than 3,050 mm the
the boiler and a valve or check vent shall be increased to 152 mm. A draft
between the check valve boiler. hood approved design shall be provided on
each boiler.
3. Feedwater may be introduced
through the blow-off connection
137
CHAPTER 7— BOILERS AND PRESSURE VESSELS
a. No Heating Boiler, except re-installed boilers Each relief valve shall have a substantial
and those exempted by these Rules and device which will positively lift the disc from
Regulations, shall hereafter be installed its seat at least 1.5 mm when there is no
unless it has been constructed, inspected pressure on the boiler.
and stamped in conformity with ASME Boiler
Construction Code or its equivalent and is c. Steam Gage
approved, registered and inspected in
accordance with the requirements of these Each steam boiler shall have a steam
Rules and Regulations. pressure gage connected to the steam
space near the boiler itself. The ranges of
b. All new installation boilers, including re the steam gage shall not be less than 1.0
installed boilers, must be installed in bar nor more than 2.0 bars.
accordance with the requirements of the
latest revision of the ASME Boiler d. Water Gage Glass and Gage Cocks
Construction Code or its equivalent and
these Rules and Regulations. Each steam boiler shall have at least one
water gage glass with the lowest visible part
42 General Requirements above the heating surfaces in primary
combustion chamber. When, in the
If in the judgment of the Engineer based on the judgment of an Engineer, the heating
following and other requirements, a steam surfaces above the low water line may be
heating boiler is unsafe for operation at the injured by contact with gases of high
pressure previously approved, the pressure temperature, the water gage shall be raised
shall be reduced, proper repair made or the until the lowest visible part of the gage glass
boiler retired from service. is above such heating surface.
No stop valve of any description shall be If any part of heating system may be closed
located between a boiler and its safety off from the remainder of the system by
valve; nor in the safety valve discharge pipe. closing a steam stop valve, there shall be
The safety valve may be located on a main
steam pipe connection at the boiler. a check valve in the condensate return pipe
from that part of the system.
b. Water Relief Valves
f. Feedwater Connection
Each Hot Water Heating or Hot Water
Supply boiler shall have one or more relief Feedwater connections shall be
valves of the spring-loaded type without disc independent of any water gage connection
guides on the pressure side of the valve.
138
CHAPTER 7 BOILERS AND PRESSURE VESSELS
and be made to the condensate return pipe Rupture discs or safety heads may be used
or reservoir of the condensate return pump. for additional protection of pressure vessels.
There should be a stop valve and a check
valve in the feedwater line at the boiler. 5.2 Existing Installations
139
CHAPTER 7— BOILERS AND PRESSURE VESSELS
140
CHAPTER 7— BOILERS AND PRESSURE VESSELS
internal deposits that may be present on the make sure that the drum has been properly
heating surface. It is recommended that the ventilated.
boiler be drained while there is sufficient heat
present t dry out interior of the boiler when 6.3.3 Fire Side
ventilated by opening manhole and handhole
covers. The walls, baffles, tubes, tubesheets, shells,
and drums should be cleaned of ash and soot
Before opening all manhole and selected to give the plant inspector an opportunity to
handhole covers, wash out plugs and water examine all parts thoroughly. Brickwork should
connections, the non-return and steam stop be removed as required by the plant inspector
valves should be closed, tagged, and in order to determine the condition of the
preferably padlocked, and the drain valves or furnace, supports, or other parts. It is not
cocks between the two valves should be necessary to remove insulation material,
opened. The feed and check valves should be masonry, or fixed parts of the boiler unless
closed, tagged, and preferably padlocked shut defects or deterioration are suspected. Where
with any drain valves or cocks located there is moisture or vapor showing through the
between these two valves opened. After covering, the covering should be removed and
draining the boiler, the blowoff valves should a complete investigation made.
be closed and padlocked. Blowoff lines, where
practical, should be disconnected between 6.3.4 External Surfaces and Parts
pressure parts and valves.
The external inspection will not require any
The plant inspector should enter the boiler to particular preparation other than giving the
make a personal examination of conditions, plant inspector convenient access to the
but before entering he should first make sure generating unit and its connections.
that it has been properly ventilated and
isolated from active systems. Where possible All external inspections by the plant inspector
portable lamps of 12V or less with current should include the examination of the boiler,
supplied from transformers or batteries should its appurtenances, and connections while the
be used. Only approved, properly guarded boiler is in service. This inspection is made
extension cords with waterproof fittings should primarily to observe operation and
be used, and all connections should be made maintenance of safety devices and operating
external to the boiler. Light fixtures should be procedures.
equipped with explosion-proof guards.
Sockets, light guards and fittings should be 6.3.5 Inspection of Internal Surfaces and Parts
properly grounded. Where it is necessary to
use higher voltage supplies, all sockets, 6.3.6 All Boilers
guards, and fittings should be properly
grounded and the circuit provided with The internal inspection of the boiler by the
appropriate ground fault service interrupters. plant inspector should include the examination
Equipment should be suitable for use in the of the physical structure with a view to
boiler or furnace to prevent explosion and determining its adequacy for service. The
ignition of combustible materials (coal dust, inspection should cover the condition of the
soot, oil, etc.) and electrical shock. entire boiler, which may include drum,
waterwalls, superheater, reheater, and
6.3.2 Water Side economizer with their fittings, as well as steam
and water connections with their fittings and
The water surfaces of drums and tubes should valves. The inspection should particularly
be preferably not be cleaned, unless include a reexamination of defects and
otherwise agreed, until after the plant previous repairs recorded on past inspection
inspector has a chance to observe the reports.
conditions.
After the drums, tubes, and other pressure
The plant inspector should enter the drum of parts have been inspected for deposits and
the boiler to make a personal examination of scale, all these surfaces should be cleaned
conditions, but before entering he should first internally either by washing, by mechanical
means, or by chemical methods as necessary
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CHAPTER 7— BOILERS AND PRESSURE VESSELS
Particular attention should also be given to the When boiler or boiler parts are suspended, the
tube ends, tubesheets, and drums. The plant supports and settings should be examined
inspector should note any corrosion or carefully, especially at point when the boiler
cracking of the tubesheets, tube ends, structure comes near the setting walls or floor
furnaces, or drums, signs of leaking tubes, to make sure that the ash and soot will not
excessive thinning of the tubes from repeated restrict the boiler and produce excessive
rolling, and the condition of any ferrules and strains due to thermal expansion under
nipples within the drums. operating conditions.
The plant inspector should note any evidence 6.3.12 Lap Joints
of corrosion or cracking due to leakage at
manholes and handholes. Boilers with riveted lap joints are apt to crack
where the plates lap in the longitudinal or
142
CHAPTER 7- BOILERS AND PRESSURE VESSELS
straight seam. If there is any sign of leakage solid particles should be inspected carefully
or other distress at this joint, it should be for erosion. The inspector should inspect
investigated thoroughly to determine if cracks baffles and walls, particularly for holes, which
exist in the seam. Any cracks noted in the may permit short circuiting of gases. The plant
shell plate are usually dangerous. inspector should inspect soot blowers, where
used, and also the boiler tubes for cutting or
6.3.13 Fire Surfaces erosion due to discharge from the blower
nozzles. The plant inspector should enter the
Particular attention should be given to plate or furnace for the inspection of the exterior of
tube surfaces exposed to fire. The plant tubes, drums, brickwork, and baffles.
inspector should observe whether any part of
the boiler has become deformed during In watertube boiler, it should be noted whether
operation by bulging or blistering. If bulges or the proper flue gas baffling is in place. The
blisters are large enough to seriously weaken deterioration of baffling often causes high
the plate or tube, or if water is leaking such a temperature on portions of the boiler structure,
defect, the boiler should remain out of service which are not intended for such temperatures
until the defective part or parts have received and may result in a dangerous condition. The
proper repairs. Careful observation should be location of combustion arches with respect to
made to detect leakage from any part of the tube surfaces should be noted to make sure
boiler structure, particularly in the vicinity of they do not cause the flame to impinge on a
seams and tube ends. particular part of the boiler and produce
overheating.
The plant inspector should inspect the setting
for cracks and settlement. Where brickwork is In vertical watertube boilers, the bridgewalls
used as insulation of steel supporting should be inspected to see that the mud drum
members, it should be examined to see that it is properly protected. In sectional and non-
is in good condition and that the air space, if sectional header-type watertube boilers, the
any, is maintained. The furnace refractory front and rear walls should be examined to
should be examined for spalling, and make sure that the bottoms of the headers are
settlement. properly protected. Tile or refractory for
protection of drums should be examined
6.3.14 Watertube Boilers carefully to make sure that drum plates are not
exposed directly to furnace flames or gases. A
The interior of the tubes should be examined defective condition of refractory and/or
for scale and deposits. Tube ends should be insulation can be detected during operation by
examined for wastage of metal, brittleness, location of hot spots on the casing or other
and short tubes. outer covering of the furnace and boiler.
Where waterwalls are used, selected 6.3.15 Firetube Boilers
handholes should be opened in the headers.
These headers should be thoroughly 6.3.15.1 Tube Defects
inspected for corrosion or deposits and
cleaned out, if necessary, to prevent failures Tubes in horizontal firetube boilers
of waterwall tubes when starting up. deteriorate more rapidly at the ends toward
the fire. They should be carefully tapped
The condition of the internal pipes in the with a light hammer on their outer surface to
steam drum should be inspected to see that determine if there has been a serious
their opening and perforations are free form reduction in thickness. They should be
deposits. All interior fittings should be inspected as far as possible either through
inspected for loose connections and damaged the handholes, if any, or inspected at the
or missing gaskets. ends.
Furnace wall headers that are partially The surface of tubes should be carefully
exposed to radiant should be inspected inspected to detect bulges, cracks, or any
carefully for any evidence of cracking. Drums, evidence or defective welds. Where there is
tubes, and headers of boilers fired by coal or a high gas velocity, the tubes may become
other fuels containing or producing abrasive eroded by the impingement by particles of
143
CHAPTER 7— BOILERS AND PRESSURE VESSELS
fuel and ash. A leak from a tube frequently The plant inspector should inspect the boiler
causes serious erosion action on a number for alignment, setting, loss of plumb, or
of tubes in its immediate vicinity. The abnormal movement such as displacement of
exterior of the tubes should be inspected for drums or other pressure parts. He should
scale and deposits. The space between the ensure that provisions are made for expansion
tubes should be made visible by lowering a and contraction of the boiler and setting, that
small light between them for the purpose of external clearances for boiler expansion are
making sure that there is no restriction of unobstructed, and that all supports are in
circulation. proper condition to carry loads imposed on
them. Permanent reference marks or
6.4.10.2 Ligaments Between Tube Holes indicators on drums and headers are
recommende d to enable rechecking their
The ligaments between tube holes in the position (both hot and cold). The plant
heads of all fire tube boilers should be inspector should verify that proper expansion
inspected. If leakage is noted, broken movement occurs as the boiler is returned to
ligaments could be the reason. service after an outage. Water sealed
expansion joints between the furnace and ash
6.4.10.3 Manholes and Other Openings pit should be examined for leaks in the baffle
and for accumulation of sludge.
The manholes and other reinforcing plates,
as well as nozzles and other flanged or Inspection should be made for evidence of
screwed connections on the boiler, should corrosion of the exterior of drums or tubes and
be inspected internally and externally to see a check made for leaks from root, stacks,
that they are not cracked or deformed. valves, or pipes. Riveted joints, butt straps,
Manhole ring surfaces should be examined and riveted heads should be examined for
for erosion and corrosion. Particular leaks or wastage. If tell tale holes are provided
attention should be given to areas of the on stays, they should be kept clean. If there is
shell where feedwater piping terminates. evidence of leakage, the stay should be
Whenever possible, observation should be replaced. Where butt straps are covered by
made from inside the boiler to check masonry or insulation, periodic testing and
soundness of pipe connections to the boiler. inspection for expansion is recommended.
All opening to external attachments, such as Supporting steel, buck stays, and tie rods
connections to the low water cutoff and should be inspected for condition and possible
opening to safety relief devices, should be shifting from place.
inspected to see that they are from
obstruction. 6.5.2 Piping
6.4.10.4 Fire Surfaces The condition of the main steam header, its
connections to the boiler, and its support units
Firetubes sometimes blister but rarely should be inspected to determine that it is
collapse. The plant inspector should properly supported, that allowance is made for
examine the tubes for such defects; if any expansion and contraction without exerting
are found to have sufficient distortion to excessive stress or strain on the pressure
warrant it, they should be replaced. parts of the boiler, and that the non return and
stop valves in good working condition.
Inspection of firetube boilers include a check
for any impingment of flame on dry sheets, All piping should be inspected for leaks; if any
particularly at the back arch of return tubular are found, it should be determined whether
boiler. The arch should be entirely clear of they are the result of excessive strains due to
the rear tube sheets with sheet metal or expansion or contraction or other causes. The
asbestos rope closing the gap. general arrangement of the piping in regard to
the provisions for expansion and drainage, as
6.5 Inspection of External Surfaces and Part well as adequate support at the proper points
should be carefully noted. There should be no
6.5.1 General pockets in the connecting piping that can hold
water unless they can be drained or equipped
with stream traps.
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CHAPTER 7— BOILERS AND PRESSURE VESSELS
The connections between individual boilers Safety is very important and should be
and the supply and return headers should be foremost in the minds of those who are
especially noted to see that any change of assigned to inspect, operate and maintain
position of the boiler due to settling or other power boilers. Only properly trained qualified
causes has not placed an undue strain on the personnel should inspect, operate and repair
piping. power boilers.
145
CHAPTER 7— BOILERS AND PRESSURE VESSELS
The plant inspector should have available an Authorized Inspector and should see that
for the benefit of the Inspector all pertinent all recommendations in such reports are
data on the boiler unit as to design, promptly and carefully considered.
dimensions, age, particulars about previous
defects, modifications, or repairs. 6.7 Repairs
A record of each inspection should be kept When repairs have been made, especially tube
in a uniform manner so that any change of replacement, the plant inspector should observe
condition can be definitely noted and whether the work has been done properly.
compared, especially with reference to the Excessive rolling of tubes, where they are
thickness of scale, corrosion, erosion, accessible, is a common fault of inexperienced
cracks, and other unusual conditions. workmen. However, when it is difficult to reach
Between periodic inspections by the the tube end and observe the extent of the
authorized Inspector, the plant inspector rolling, they are frequently under-rolled. This
should closely observe the operation and inadvertently results in separation of the parts
condition of the boiler and should report and leakage.
immediately to the plant engineer or plant
management any serious defects, doubtful When damage to pressure parts is encountered,
conditions, or unusual occurrences. requiring repairs by processes such as welding,
the review and acceptance of an Authorized
6.6.3.2 Permanent Log Book Inspector should be obtained on the manner in
which the repair is to be made. It may also be
A permanent log book should be provided necessary to contract the Authorized Inspector
for each power boiler in the plant to record prior to retubing and rerolling of tubes. A
maintenance work, inspections, tests, hydrostatic test may be required if repairs are
repairs, and other pertinent data. Brief made, as required by the Authorized Inspector.
details of repairs and other work performed
on the boiler should be recorded. 6.8 Hydrostatic Test.
Performance of tests and inspections
required by jurisdictions or insurance When there is a question or doubt in the extent
companies should also be recorded. of a defect found in a boiler, the Authorized
Inspector, in order to more fully decide upon its
6.6.3.3 Daily Log seriousness, may request the application of a
hydrostatic test.
A daily log for scheduling and recording
work performed and maintenance, testing, Hydrostatic test pressure should not exceed 1-
and inspection is recommended. The routine 1/2 times the maximum allowable working
work normally performed on power boilers is pressure. During the test, the safety valves
listed. As each portion of the work is should be gagged or removed from the boiler as
completed, the person performing the work should all controls and appurtenances unable to
should enter the date and his initials in the withstand the test pressure without damage. It
appropriate spaces. is suggested that the minimum temperature of
the water be 70°Fand a maimum of 12OF.
The plant inspector should note particularly
any evidence or carelessness in the For new generation Boilers, (Boilers used for
maintenance and operation of the boiler and utility power generation) wher hydrostatic testing
related equipment. at 1.5 times Maximum Allowable Pressure
entails costly downtimes and requires
The plant inspector should recommend modification of section, thereby causing major
immediate correction of any unsafe disruptions in plant operations tht adversely
conditions or undesirable practices that may affect economic activities, the following testing
be discovered and should report promptly procedures is hereby adopted:
and fully on the results of his inspection to
his immediate superiors. a. In new installations, before operation,
hydrostatic test at 1.5 times design
The plant inspector should be furnished a pressure.
copy of all reports of inspections made by
146
CHAPTER 7— BOILERS AND PRESSURE VESSELS
The following features of all boilers should be Authorized inspector is defined in 6.1 a.
checked during each inspection: When certification and/or licensing are
required by the jurisdictional authorities, the
a. safety / relief valve nameplate capacity, Authorized Inspector is normally the individual
set pressure, connection to boiler, who will make the required inspections for the
discharge line, testing; issuance of the certificate and/or license to
operate.
b. low water fuel supply cut-out, level control
or regulator, water feeder controls When required by the jurisdictional authority
combined / separate, stop valves in the Authorized Inspector should make an
connection lines, testing; internal and external inspection of all power
boilers at least once each year and any
c. controls operative, control maintenance additional inspections that the Authorized
Inspector may deem necessary. In some
d. flue and damper arrangement, combustion jurisdictions, the annual internal inspection
safeguards; may be extended, if certain conditions are
met.
e. burner refractory, flame impingement,
baffles, lining, supports; When required by the jurisdictional authority,
the Authorized Inspector should make an
f. source of feedwater, condition of inspection prior to placing boilers in service for
feedpump, feedwater treatment; the first time. This inspection should be as
outlined in 6.2.
g. condensate return system, amount
returned; The Authorized Inspector should review, for
acceptance, the manner in which repairs or
h. review of boiler maintenance and alterations are to be made to ensure that
operating logs; Code integrity of the power boiler is
maintained.
i. buried line, line leakage;
The Authorized Inspector may require and
j. steam pipe supports, piping free to witness a hydrostatic test whenever repairs
expand and contract; have been made, or when there is a question
147
CHAPTER 7— BOILERS AND PRESSURE VESSELS
or doubt about the extent of a defect found a. Blow-off piping from a power boiler or
during inspection of a power boiler. miniature shall not discharge directly into
a sewer. A blow-off tank shall be used
The plant inspector should accompany the where conditions do not provide an
Authorized Inspector during his inspection. adequate and safe open discharge.
6.11 Low Water Fuel Cut-Offs b. Blow-off tanks hereafter installed, if made
of metal shall have a plate thickness of not
All automatically-fired system or vapor boilers, less than 8 mm diameter and shall be
excepting boilers a constant attendant who designed for a minimum working pressure
has no other duties while the boilers is in of 0.345 MPa or 3.45 bars.
operation, shall be equipped with an automatic
low-water fuel cut-off and/or water feeding c. The outlet from the blow-off tank shall be
device so constructed that the water inlet twice the area of the inlet pipe and made
valve cannot feed water into the boiler through to extend internally within 203 mm from
the float chamber, and so located as to the bottom of the tank.
automatically cut off the fuel supply and/or
supply requisite feedwater when the surface of d. A vent pipe at least four (4) times the area
the wall falls to the lowest safe water line. of the inlet pipe shall lead to the outer
This point should be not lower than the bottom atmosphere.
of the water glass.
e. Vents shall be as direct as possible to the
Such a fuel of feedwater control device may outer air and discharge at a safe location.
be attached direct to a boiler or to the tapped There shall be no valve or other possible
openings provided for attaching a water glass obstructions such as water pockets,
direct to the boiler, provided that such between the tank and the discharge end
connections from the boiler are non-ferrous of vent pipe.
tees or Y’s not less than 12.7 mm diameter
pipe size between the boiler and the water f. All pipe connections between the tank and
glass so that the water glass is attached direct the boiler shall be as direct as possible
and as close as possible to the boiler; the and shall conform to ASME Boiler
straightway tapping of the Y or tee to take the Construction Code or its equivalent.
water glass fittings, the side outlet of the Y or
the tee to take the fuel cut-off or water feeding g. For convenience in cleaning the tank, a
device. The ends of all nipples shall be manhole or an access opening shall be
reamed to full size diameter. Designs provided.
embodying a float bowl shall have a vertical
straight-a-way valve drain pipe at the lowest h. Where a blow-off tank is not vented as
point in the water equalizing pipe connections specified above, it shall be constructed for
by which the bowl and equalizing pipe can be a pressure equal to that allowed on the
flushed and device tested. boiler to which it is attached or shall be
equipped with a safety valve or valves of
6.12 Safety Gadgets I Cut-Outs sufficient capacity to prevent the pressure
from exceeding the safe working pressure
No person shall remove or tamper with any of the tank.
safety gadgets or components prescribed by
these rules except for the purpose of making 7.2 Location of Blow-Offs. The discharge of
repairs. The resetting of safety gadgets or safety valves, blow-off pipes and other outlets
components shall be done in the presence of shall be located so as to prevent injury to
an authorized representative of the personnel or avoid making a nuisance to the
government agency concerned. surrounding vicinity.
148
CHAPTER 7— BOILERS AND PRESSURE VESSELS
inspeclion of the entire shell and heads of b. A suitable screen or guard shall be
the vessel can be made. provided around high-tension bushing and
a sign posted warning of high voltage.
b. Supports. Each unfired pressure vessel This screen or guard shall be located that
shall be supported by masonry or it will be impossible for anyone working
structural supports of sufficient strength around the generator to accidentally come
and rigidity to safely support the vessel in contact with the tension circuits. When
and its contents. There shall be no adjusting safety valves, the power circuit
vibration in either the vessel or its to the generator shall be open. The
connecting piping. generator may be under steam pressure
but the power line shall be open while the
7.3 Pressure Reducing Valves. operator is making the necessary
adjustments.
a. Where pressure reducing valves are used,
one or more relief safety valves shall be c. Each kW electrical energy consumed by
provided on the low pressure side of the an electric steam generator operating at
reducing valve in case the piping or maximum rating shall be considered the
equipment on the low pressure side does equivalent of 0.093 m 2 of heating surface
not meet the requirements for the full of a fire tube boiler when determining the
initial pressure. The relief or safety valves required amount of safety valve capacity.
shall be located adjoining to or as close as
possible to the reducing valve. Proper Section 8.0 Other Testing Methods
protection shall be provided to prevent
injury or damage caused by the escaping For existing boilers within the five (5) year interval of
steam form the discharge of relief or hydrostatic testing, any one of the following methods
safety valves if vented to the atmosphere. may be undertaken. This, however, is not mandatory.
d. It is mandatory that a pressure gage be The test is based on the amount of time it takes
installed on the low-pressure side of a generated sound waves to pass through a
reducing valve. material and back to the source after being
reflected. The difference in time is translated
7.4 Electric Steam Generators. All appliances into thickness measurement of the material
required for electric steam generators shall be being tested. The test shall be performed on all
attached in accordance with the following: tubes with any indication of erosion. Tube
below recommended nominal wall thickness
a. A cable at least as large as one of the shall be repaired using weld overlaid or replaced
incoming power lines to the generators as per currently practiced repair procedures.
shall be provided for grounding the
generator shell. This cable shall be 8.3 Radiographic Testing
permanently fastened on some part of the
generator and shall be grounded in an X-rays shall be used to penetrate and record on
improved manner. film the imperfection or defects in the boiler tube
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CHAPTER 7— BOILERS AND PRESSURE VESSELS
150
CHAPTER 8— HEATING, VENTILATING, REFRIGERATION AND AIRCONDITIONING
Chapter 8
surroundings, thereby producing the cooling effect for the transmission of heat without a change in its
(also known as the Refrigerating effect). state, having no flash point or a flash point above
65.6°C as determined by the American Society of
Air Conditioning the process of treating air so as to
—
Testing Materials method D93.
control simultaneously its temperature, humidity,
cleanliness and distribution to meet the requirements Compressor a mechanical device used in
-
of the conditioned space. refrigeration system for the purpose of increasing the
pressure upon the refrigerant.
Ventilation the process of supplying or removing air
by natural or mechanical means to or from any space. Condenser a vessel or arrangement of pipe or
-
Such air may or may not have been conditioned. tubing in which vaporized refrigerant is liquefied by the
removal of heat.
Humidity — unless otherwise stated will mean the
relative humidity in per cent. This is the ratio of the Condensing Unit a specific refrigeration machine
-
actual (measured) partial pressure of the water vapor combination for a given refrigerant, consisting of one
in the air mixture to its saturation pressure at the same or more power-driven compressors, condensers, liquid
dry bulb temperature. This is also the ratio of the receivers (when required) and the regularly-furnished
actual weight of moisture per cubic meter of mixture to accessories.
the saturated water vapor per cubic meter of mixture
at the same dry bulb temperature. Design Working Pressure the maximum allowable -
index, which combines into a single value the effect of Evaporator that part of the system in which liquid
-
temperature, humidity and air movement on the refrigerant is vaporized to produce refrigeration.
sensation of warmth or cold felt by the human body.
The numerical value is that of the temperature of still Expansion Coil - an evaporator constructed of pipe or
saturated air which could induce an identical tubing.
sensation. The wide range of effective temperature is
indicated on graphical representation of comfort zone. Fusible Plug a device having a predetermined
-
151
CHAPTER 8— HEATING, VENTILATING, REFRIGERATION AND AIRCONDITIONING
Machinery Room - a specific room in which is refrigerating system in which the refrigerant
permanently instalied and operated Refrigerating and gas evolved in the evaporator is taken up in
Air Conditioning machinery. Closets solely contained an absorber and released in a generator upon
within and opening only into a room shall be the application of heat.
considered a part of such room.
b. Refrigerating System, Brine an indirect
—
a. Doors which are tight-fitting, fire-resisting, and refrigerating scheme for cooling by a mist or
self-closing. spray of brine.
b. Walls which are vapor-tight and of approved fire d. Refrigeration System, Cascade —one
resistive construction. having two or more refrigerant circuits, each
with a pressure-imposing element, condenser
c. An exit door which opens directly to the outer air and evaporator, where the evaporator of one
or through a vestibule-type exit equipped with circuit cools the condenser of another (lower
self-closing, tight-fitting doors. temperature).
d. Exterior openings which, if present, are not e. Refrigerating System, Central Point a
—
under any fire escape or any open stairway. system with two or more low sides connected
to a single, central high side; multiple system.
e. All pipes piercing the interior walls or floor of
f.
such room, tightly sealed to the walls or floor
through which they pass.
I
outside to stop the action of the refrigerator g. Refrigerating System, Compression a -
Piping — pipe or tube mains for interconnecting the i. Refrigeration System, Flooded a
-
various parts of a Refrigerating System. refrigerating system in which only part of the
refrigerant passing over the heat transfer
Pressure Limiting Device a valve held closed by a
—
separated from the vapor and recirculated.
spring of other means and designed to automatically
relieve pressure in excess of its setting. j. Refrigerating System, Indirect - a
refrigerating system in which a liquid, such as
Pressure Vessel any refrigerant containing
—
brine or water cooled by the refrigerant, is
receptacle of a refrigerating system, other than the
152
CHAPTER 8— HEATING, VENTILATING, REFRIGERATION AND AIRCONDITIONING
circulated to the material or space refrigerated Tenant as herein used a tenant shall be construed
-
or is used to cool air so circulated. as a person, firm, or corporation possessed with the
legal right to occupy premises.
k. Refrigerating System, Mechanical a -
refrigerating system employing a mechanical Welded Joint for the purpose of this Code, a welded
-
compression device to remove the low joint is a gas-tight, obtained by the joining of metal
pressure refrigerant enclosed in the low parts in the plastic or molten state.
pressure side and delivers it to the high
pressure side of the system. Section 2.0 Air Conditioning and
Ventilation Standards
I. Refrigerating System, Multiple - a
refrigerating system using the direct method in 2.1 The temperature and humidity of the air to be
which refrigerant is delivered to two or more
used for comfort cooling shall be maintained at
evaporators in separate rooms or 20°-23.3°C effective temperature at an air
refrigerators. movement of from 4,570 to 7,620 mm/mm within
the living zone and 55 to 60% relative humidity.
m. Refrigerating System, Single-Package a -
153
_____________________
2.5 The quality of air used to ventilate the space 2.8 Refrigerant Classifications:
during the occupancy shall always be sufficient
to maintain the standards of air temperature, air Group 1:
quality, air motion and air distribution. Carbon Dioxide 2
CO
Ventilation requirements shall conform to the Dichlorodifluoromethane R-12 F
2
CCI
following Table 8.2. Dichloromonofluoromethane R-22 CHCL
F
2
Dichlorotetra fluoroethane R114 2 CL
C
4
F
Table 82 Dichloromethane CL
Carrene 2
Ch
Outdoor Air Reauirement No. I
Liters per Trichloromonofluoromethane R-1 I F
3
CCL
Application second/person
Recommended Group 2:
Apartment, average 12 Ammonia 3
NH
Banking Space 9.5 Dicholoroethylene CI
H
2
C
Barber Shop 11.8 Ethyl chloride CI
3
CH
Beauty Parlor 12 Methyl Formate 3
HCOOCH
Board Room 11.8 Sulfur dioxide 2
SO
Cocktail Bar 14
Department Store 7.5 Group 3:
Director’s Room 11.8 Butane C
1
H
4 0
Drug Store 7.5 Ethane 68
H
2
C
Factory 7.5 lsobutane )
3
(CH CH
5 & 10 Stores 7.5 Propane 8
H
3
C
Funeral Parlor 11.8
Hospital, Private Room 11.8 2.9 Locations in which Refrigeration Systems may
Hospital, Ward 9.5 be placed are grouped by occupancy as follows:
Hotel Room 17
Laboratories 9.5 a. Institutional occupancy like hospitals,
Meeting Room 11.8 asylums, sanitariums, police stations, jails,
Offices, General 9.5 court houses with cells, etc.
Restaurant, Cafeteria 9.5
Dining Room 9.5 b. Public assembly like auditorium, assembly
Shop, Retain 7.5 rooms, ball rooms, broadcasting studios,
Theater 7.5 churches, department stores, fraternity,
halls, libraries, theaters, etc.
2.6 The desirable temperature in air conditioned
spaces increases as the outdoor temperature c. Residential occupancy apply to portions of
increases as shown in Table 8.1. buildings in which sleeping accommodations
are provided.
2.7 The quantity of outdoor air required to control
body odors satisfactorily decreases as the d. Commercial occupancy applies to portions
volume space per occupant increases. of buildings used for transactions of
Recommended rates of outdoor air supply for business, for rendering professional
different volumes of spaces per occupants are services or for supply of food and drinks.
as follows:
e. Industrial occupancy applies to entire
Table 8.3 building occupied by single tenant, for
Minimum Outdoor Requirements to Remove manufacturing, processing or storage of
Objectionable Body Odors for Sedentary Adult Workers materials or products including chemical,
food, candy, ice cream factories, ice-making
Air Space per Person Outdoor Air Supply per plants, meat packing plants, refineries,
3
M Occupant Ips perishable food warehouses and similar
3 14 occupancies.
6 10
9 8 f. Mixed occupancies applying to a building
14 4 occupied or used for different purposes in
different parts.
154
CHAPTER 8 HEATING, VENTILATING, REFRIGERATION AND AIRCONDITIONING
155
CHAPTER 8- HEATING, VENTILATING, REFRIGERATION AND AIRCONDITIONING
156
CHAPTER 8— HEATING, VENTILATING, REFRIGERATION AND AIRCONDITIONING
1. Room Thermostat;
Section 3.0 Duct System and Accessories
2. Solenoid Valve (Liquid Line);
3. Compressor High & Low Pressure
3.1 Design
Cut Off;
4. Compressor Low Oil Pressure Cut
a. Ducts system shall be designed and
Off (for compressors with positive
installed in accordance with a recognized
lubrication).
and acceptable method such as contained
in ASHRAE guide or applicable manuals of
b. Chilled Water
the SMACNA and shall comply with National
1. Room Thermostats;
Fire Protection Pamphlet No. 90-B, except
2. Face & Bypass Damper with
as other wise provided herein.
modular motor or motorized chilled
water mixing valve;
3.2 Fabrication I Construction
3. Chiller Flow Switch;
4. Chiller Low Water Temperature Cut
a. Ducts shall be constructed entirely of non-
Off;
combustible materials such as steel, iron,
5. Compressor Low Oil Pressure Cut
aluminum or other approved materials.
Off (for compressors with positive
lubrication).
6. Compressor high and low pressure
cut-off
157
CHAPTER 8- HEATING, VENTILATING, REFRIGERATION AND AIRCONDITIONING
SPLITTER
ROD
158
_________
g. Only fire retarding materials conforming to Plenum chamber which conform to all the
the standards set by the Underwriters’ requirements for ducts may be located in
Laboratories (UL), National Fire Protection any such portion of the building. Such
Association and the Fire Code of the chambers shall not be used for storage or
Philippines, shall be used for duct insulation occupational purposes. Public exit halls and
and duct liners. corridors in hotels, hospitals, institutions,
office building and similar occupancies and
h. Insulation materials for air ducts, pipes, in multi-family houses used for passage of
conduits, etc., shall be of sufficient thickness return air shall provide an air velocity not to
so that the surface temperature of the duct, exceed 0.5 meter per second within the
pipe, etc., shall not be lower than the dew living zone.
point of the surrounding air.
e. Only fire retardant materials shall be used
Ducts shall be made reasonably tight inside of ducts.
throughout and shall have no openings
other than those required for the proper f. Insulation materials for air ducts, pipes,
operation and maintenance of the system. conduits, etc. shall be with sufficient
thickness so that the surface temperature of
j. Return ducts, other than vertical, shall be the duct, pipe, etc. shall not be lower than
provided with access doors or openings to the dew point of the surrounding air.
facilitate the cleaning of possible
accumulation of dust and combustible
materials in them when occupancy is not 25mm STRAPPING BAND
FIG. 8.3.4
b. Where ducts pass thru walls, floors or
DUCT INSULATION DETAILS
partitions, the space around the duct shall
be sealed with a material fire resistant
property equivalent to that of the wall, floor
or partition, to prevent the passage of flame g. Ducts shall not be built into a building in
or smoke. such a way as to impair the effectiveness of
the fire proofing around steel or iron
c. Ducts which pass thru floors or fire proof structural members, such as placing the
constructions, semi-fire proof construction, ducts between the fire proofing and the
or heavy timber construction, in which members protected.
vertical openings are generally protected,
shall be encased in 100 mm hollow clay tile, h. Ducts shall not be located where they will be
gypsum block or their equivalent. Such subject to damage rupture. Where so
construction, however, shall not be required located, they shall be suitably protected.
for branches, which are cut off from the
main portion of the duct by approved fire Ducts shall be substantially supported.
dampers. Hangers and brackets for supporting ducts
shall be metal. Ducts exposed to the
d. No attic, basement or concealed space in a weather shall be wrapped with weather
building shall be used as an integral part of proofing materials.
a duct system unless it conforms to all the
requirements for ducts. j. Approved fire dampers shall be provided
where the air ducts penetrate or terminate at
the openings in the walls or partitions these
159
CHAPTER 8— HEATING, VENTILATING, REFRIGERATION AND AIRCONDITIONING
to have a fire resistance rating of 2 hours or (10°C) above the maximum temperature that
more. Approved fire dampers shall be would normally be encountered with the
provided in all air transfer openings in system in operation or shut down. Hinged
partitions that are required to have fire dampers shall be equipped with spring
resistance rating in which other openings catches and pins of hinges shall be of
are required to be protected. corrosion resistant materials.
k. The passing of supply and return ducts thru n. An approved fire damper shall be provided
fire walls should be avoided wherever an opening through a required fire partition.
possible. When ducts or the outlets or inlets
to them pass through fire walls, they shall be o. Where duct system serve two or more
provided with automatic fire dampers on floors, approved fire dampers shall be
both sides of the fire wall through which they required at each direct outlet and in each
pass. On small openings not exceeding 457 branch duct at its junction with the main
mm in diameter, 9.5 mm steel plates may be vertical duct. Dampers are not required in
used instead of fire dampers. branch duct having a cross sectional area of
less than 129 cm 2 which supply only air
See page 170 of 2003 conditioning units discharging air or not over
1,220 mm above the floor.
Fig. 8.3.5
p. In systems of over 425 m 3 per minute
capacity serving areas where large numbers
Duct Hangar Detail of people congregate or areas having
valuable contents particularly subject to
smoke damage, except when system is
located on the same floor that it serves, it is
recommended that approved smoke
dampers be installed in the main supply duct
and main return duct. Such dampers should
be arranged to close automatically when the
system is not in operation and also by
INSULATION
manual emergency motor stop or by
-
ANGLE BAR
application of a smoke detecting apparatus.
160
CHAPTER 8— HEATING, VENTILATING, REFRIGERATION AND AIRCONDITIONING
Section 4.0 Heat Gain Calculations Section 6.0 Air Intake and Outlets
4.1 Calculations shall be made in accordance with 6.1 Re-circulating air intakes shall be located at
the American Society of Heating Refrigerating above the floor, except that protected floor inlets
Air Conditioning Engineering (ASHRAE) Guide, may be permitted under seats in theaters.
Air Conditioning and Refrigerating Institute When located less than 2,130 mm above the
Standards, the applicable manuals of the floor, inlet and outlet openings shall be protected
National Warm Air Heating and Air Conditioner by a substantial grill or screen, thru the opening
Association, or other recognized and acceptable of which 13 mm sphere will not pass.
methods.
Fresh air intakes shall be protected by screens
Section 5.0 Refrigeration System of corrosion resistant material not larger than 13
mm mesh. Air shall not be re-circulated from
5.1 Where condenser cooling water causes any spaces in which objectionable quantities of
excessive corrosion, scaling, or obstruction anesthetic gases, toxic gases, flammable
within the piping or equipment, suitable water- vapors, flying, dust or bacteria laden air are
treatment means may be required and piping given off.
used for conveying condenser cooling water
shall be zinc coated. (galvanized copper, or Care should be exercised in choosing the
other corrosion-resistant material acceptable to location of fresh air intakes to avoid drawing in
the FHA field office of the Chief Underwriter). combustible materials to minimize the hazard
from fire in other structures and air conditioning
5.2 All exposed refrigeration piping located less than those listed under Section 8.5.1.
1830 mm above any floor or outside grade shall
be suitably protected to prevent damage to Section 7.0 Air Filters
piping and injury to persons.
7.1 Air filters shall be of approved types that will not
5.3 Clearance shall be provided for all construction burn freely or emit large volumes of smoke or
to permit proper operation, adjustments, other objectionable products.
replacement and repair of equipment.
Liquid adhesive tanks into which removable
5.4 Suitable means shall be provided for the filters are dipped should preferably be located
collection and disposal of condensate from the outside the building or in a separate fire resistive
equipment. The condensate drain shall be at room.
least 19 mm nominal pipe size and shall be
copper, galvanized, steel, or other corrosion- Liquid adhesive coatings used on air filters shall
resistant materials. have a flash point not lower than 177°C. Air
filters shall have a minimum rating of 60%
5.5 Where the cooling coil or air conditioning unit is filtering efficiency and higher efficiency for
located above a living space, or where structural special applications.
damage may result from condensate overflow,
an additional waterlight pan of corrosion- Filters shall be sized to provide not less than
resistant metal shall be installed beneath the 0.093 m2 of total face area per 142 lps of air and
cooling coil or unit to catch overflow and shall be readily accessible for cleaning or
separate drain, or one pan with standing replacement.
overflow and separate drain maybe provided
with a drain pipe, minimum of 19mm nominal Section 8.0 Noise Abatement
pipe size, discharging at a point which can be
readily observed. Condensate drains shall not 8.1 As a partial index and guide, the sound level
be directly connected to a plumbing drainage due to operation of the equipment, as measured
system. on the 40 decibel weighted network in the center
of conditioned space 914 mm above the floor
5.6 Refrigerating piping, with or without insulating shall not be higher than 45 decibels for a
covering shall be exposed to view, excepting for normally furnished room of 50 decibels for an
mechanical protection. unfurnished room.
161
CHAPTER 8— HEATING, VENTILATING, REFRIGERATION AND AIRCONDITIONING
Section 9.0 Cold Storage and 10.5 Cast iron shall conform to American Society for
Testing Materials, designation A-i 36-30 Class B
Refrigeration
higher strength gray iron with not less than 206
2 tensile strength.
700 N/rn
9.1 Cold storage shall mean the storage or keeping
of all articles of food at a temperature, not to
10.6 Bushing may be used in fittings when the
exceed —6°C, above 00 in a cold storage
reduction is two or more pipe sizes. For single
warehouse; cold storage warehouse shall mean
pipe size reduction, reducing fittings must be
any place artificially cooled at a temperature not
used.
to exceed —6°C in which all articles of food may
be stored or placed for an indefinite period of
10.7 Pipe bends shall be substantially circular in
time.
section and free from injurious wrinkles, kinds
and creases. They shall not be constructed as
9.2 Refrigerated Storage shall mean the storage or
barring corrugated pipe bends made of suitable
keeping of articles of food at a temperature not
material.
to exceed above zero in refrigeration, ice boxes,
and 4°C other similar devices artificially cooled
10.8 Standard pipe size copper or red brass not less
at a temperature not to exceed 4°C in which
than eighty (80) percent may be used.
preserved meat, pork, fowl, butter, shrimps,
lobsters, crabs, etc., may be stored or kept.
10.9 Copper tubing used for refrigerant piping
erected on the premises shall conform to
9.3 An ice plant is closely associated to Cold Materials
American Society for Testing
Storage and Refrigerated Storage but should be
designation B-88-33, grades K or L for
treated as a Process Plant rather than in an
dimensions, and shall be absolutely free from
accessory to a building or buildings.
scale and dirt.
Section 10.0 Refrigerant Piping, Valves, 10.10 Copper tubing used for refrigerant piping
Fittings and Related Parts erected on and 16 mm nominal sizes in the
same standard series as grades K or L of
10.1 Materials American Society for testing and Materials
designation B-88-33, shall be considered as
All materials used in the construction and meeting the requirement of Section 8.10.8.
installation of Refrigerating System shall be
suitable for the refrigerant used, and no 10.11 Soft annealed copper tubing used for refrigerant
materials shall be used that will deteriorate due piping erected on the premises shall not be used
to the chemical action of the refrigerant or the in sizes larger than 18 mm nominal size. It shall
oil, or the combination of both. conform to grades K or L of American Society
for Testing Materials designation B-88-33.
10.2 Standard weight steel or wrought iron pipe may
be used for Design Working Pressures not 10.12 Rigid metal enclosures shall be provided for soft
exceeding 1,724.0 kPa, provided lap welded or annealed copper tubing used for refrigerant
seamless pipe is used for sizes larger than 500 piping erected on the premises, except that
mm (iron pipe size) and extra heavy pipe is used flexible metal enclosures may be used at bends
for liquid lines for sizes 38 mm (iron pipe size) or terminals if not exceeding 1,830 mm in
and smaller. length.
10.3 Pipe joints may be screwed, flanged or welded. 10.13 Threaded joints on copper or brass pipe of
Screw joints shall conform to U.S. or R.P. standard pipe size shall be made with extra
Standard. Exposed threads shall be tinned or heavy brass fittings.
otherwise coated to inhibit corrosion.
10.14 Joints on annealed copper tubing not exceeding
10.4 d.Valves, flanges and fittings may be made of 19 mm in outside diameter may be made with
cast iron, malleable iron, bronze or brass, and flared compression fittings or approved type,
shall be of the design and material listed by the provided that all such fitting shall be exposed for
manufacturer for the particular refrigerant visual inspection.
service.
162
CHAPTER 8— HEATING, VENTILATING, REFRIGERATION AND AIRCONDITIONING
10.l5Joints on hard drawn copper tubing, if of the d. Stop valves placed where it is not obvious
sweated capillary type, may be made with an what they control shall be suitably labeled.
alloy having a melting point greater than 538°C Numbers may be used to label the valves
or with solder melting at a point below 240°C but provided a key to the numbers is located
above 177°C. near the valves.
10.16 Fittings used in sweated capillary joints shall be 10.20 Pipe and Tube Supports
cast red bras or die pressed brass of copper or
wrought brass or copper, or extruded brass or a. All refrigerant piping shall be securely
copper. supported by means of metal hangers,
brackets, straps, clamps or pedestals, in
10.17 Soldered joints in pipe or tubing erected on the such manner as to relieve joints of harmful
premises shall remain mechanically intact when strains and vibration. The supports shall be
subjected to a pull apart test equivalent to used for no other purpose. Hangers for
pressure of not less than 2,067 kPa gage with a refrigerant piping above 22 mm outside
temperature of not less than 149°C, except that diameter shall not be less than 0.806- cm2
this requirement shall not apply to soldered cross section.
joints in pipe or tubing of 13 mm nominal size or
smaller when used in systems containing not 10.21 Location of Refrigerant Piping
more than 9.09 kg of refrigerant.
a. Refrigerant piping crossing an open space
10.l8Any evaporator located in an air duct of an air which affords passageway in any building
conditioning system for human comfort shall be shall not be less than 2,290 mm above the
constructed to withstand without leakage a floor unless against the ceiling of such
temperature of 538°C. space.
1. Each inlet and each outlet pipe of 10.22 Design and Construction
each compressor.
a. Every part of a Refrigerating System, except
2. Each inlet and each outlet pipe of pressure gauges and control mechanism,
each liquid receiver. shall be designed, constructed, and
assembled to withstand the test pressures
3. Each liquid and each suction branch specified in Table 8.7, without being
header. stressed beyond one-third (1/3) of its
ultimate strength.
c. Stop valves with soft annealed copper
tubing or hard drawn copper tubing 19 mm b. Equipment listed by a recognized
nominal size or smaller shall be securely engineering testing laboratory having a
mounted independent of tubing fastenings follow-up inspection service, shall be
or supports. considered as conforming with the
requirements of Section 8.9.21.3.
163
CHAPTER 8— HEATING, VENTILATING, REFRIGERATION AND AIRCONDITIONING
c. Refrigerant containing vessels which are not discharge capacity determined by test with
a part of equipment listed by a recognized the outlet open to the atmosphere and with
engineering testing laboratory having a a differential pressure across the restraining
follow-up inspection service shall be member equal to twice the marked pressure
constructed in accordance with the rules of setting of the pressure relief valve.
Chapter 7 (Unified Pressure Vessel).
b. The rated discharge capacity of rupture
d. Every systems, except as provided in members and discharge piping shall be as
Sections 10,V.d., 11.A and 11.B, shall be given in Table 8.6.
protected by a pressure relief device unless
so constructed that pressure due to fire 11.7 Required Capacity
conditions will be relieved safely by soldered
joints, lead gaskets, fusible plugs, or their a. The minimum required rated discharge
parts of the system. capacity of pressure relief device for a
refrigerant containing vessels shall be
Section 11.0 Pressure Relief Devices determined by the following formula:
11.2 Each pressure vessel having a gross volume of L = Length of the vessel in mm.
0.142 m3 or less, containing liquid refrigerant
and which may be shut off by valves from all f = Factor dependent upon kind of
other parts of a refrigerating system, shall be refrigerant as follows:
protected by an approved pressure relief device
or an approved fusible plug. Kind of Refrigerant Value of “f’
Ammonia(NH3) 0.041
11.3 The requirements of Section 10.V.d and 1.1 Dichlorodifluoromethane,(R-1 2, R-22) 0.163
shall not apply to flooded evaporators located in R-134a, R500
a refrigerator cabinet.
11.8 Pressure Setting Test
11.4 Each pressure vessel shall have the Design
Working Pressure stamped thereon if its gross a. The pressure setting of relief devices for
volume exceeds 0.142 m
.
3 refrigerant containing vessels shall be tested
with the outlet open to the atmosphere and
11.5 Compressors operating above 103.35 kPa the relief device shall function at a pressure
gauge and having a displacement exceeding not more than ten (10) percent above the
2.83 m3 per minute shall be equipped by the pressure marked thereon, if such marking is
manufacturer with a pressure relief device of 689 kPa or more, or at not more than 6839
adequate size to prevent rupture of the kPa above the pressure marked thereon, if
compressor, located between the compressor such marking is less than 689 kPa.
and stop valve on the discharge side. The
discharge from such relief device may be vented 11.9 Marking
to the atmosphere or into the low pressure side
of the systems. a. All pressure relief valves for refrigerant
containing vessels shall be set and sealed
11.6 Capacity Rating by the manufacturer. The name or trade of
the manufacturer, the pressure setting
a. The rated discharge capacity of a pressure expressed in kPa, the rated discharge
relief valve, expressed in points of air per capacity expressed in kilogram of air per
minute shall be one-fifth (1/5) of its minute, and the minimum equivalent length
164
CHAPTER 8— HEATING, VENTILATING, REFRIGERATION AND AIRCONDITIONING
of discharge piping that can be attached to a. Where ammonia is used, the discharge may
the pressure relief valve without loss of be into a tank of water which shall be used
discharge capacity, shall be cast or stamped for no purpose except ammonia absorption.
on the device, or on the metal plate At least 3.78 liters of fresh water shall be
permanently thereto. provided for every 0.45 kg of ammonia in
the system. The water used shall be
b. Each rupture member for refrigerant prevented from freezing. The tank shall be
containing pressure vessels shall have cast substantially constructed shall be greater
or stamped on the device or on a metal than one-half (1/2) the height. The tank
plate of the manufacturer and the bursting shall have a hinged cover, or, if of the
pressure of the rupture member expressed enclosed type, shall have vent hole at the
in Pascal or Kilopascal. top. All pipe connections shall be through
the top of the tank only, the discharge pipe
11.10 Installation Requirements from the pressure relief valves shall
discharge the ammonia in the center of the
a. A rupture member may be located between tank near the bottom.
a pressure relief valve and a pressure
vessel. 12.4 Sulfur Dioxide Discharge
b. No stop valve shall be located between any a. When sulfur dioxide is used, the discharge
automatic pressure relief device and the part may be into tank of absorptive brine which
or parts of the system protected thereby, shall be used for no purpose except sulfur
except when the parallel relief devices dioxide absorption. There shall be 3.378
mentioned in Section 10.V.d are so liters of standard dichromate brine 1.14 kg
arranged that only one can be rendered sodium dichromate per 3.78 liters for every
inoperative at a time for testing or repair 0.46 kg of sulfur dioxide in the system.
purposes. Brines made with caustic soda or soda ash
may be used in pace of sodium dichromate
c. All pressure relief devices shall be provided the quantity and strength give the
connected as nearly as practicable directly equivalent sulfur dioxide absorbing power.
to the pressure vessels or other parts of the The tank shall be substantially constructed
system protected thereby, and shall be of not less than 3.15 mm iron or steel. The
placed above the liquid refrigeration level. tank shall have a hinged cover, or if of the
enclosed type, shall have a vent hole at the
d. The seats and discs of pressure relief top. All pipe connections shall be through
device for refrigerant containing vessels the top or the tank only. The discharge pipe
shall be constructed of suitable material to from the pressure relief valve shall
resist refrigerant corrosion. discharge the sulfur dioxide in the center of
the tank near the bottom.
Section 12.0 Discharge from Pressure
Relief Devices Section 13.0 Pressure Limiting Devices
12.1 Pressure relief devices and fusible plus on all 13.1 Pressure limiting devices are required on all
systems containing more than 13.64 kg of systems containing more than 9.09 kg of
refrigerant, except those used to protect refrigerant and operating above atmospheric
compressors, shall discharge to the outside of pressure, and on all Water Cooled Systems so
the building in an approved manner. constructed that the compressor or generator is
capable of producing a pressure in excess of the
12.2 The size of the discharge opening and pipe from test pressure.
the pressure relief device shall not be less than
the size of the relief device inlet. The discharge 13.2 Pressure limiting devices shall stop the action of
from more than one relief device may be run into the compressor at a pressure less than ninety
a common header, the area of which shall be (90) percent of the pressure relief devices
not less than the sum of the areas of the pipes setting but more than ninety (90) percent of the
connected thereto. test pressure given in Table 8.6.
165
CHAPTER 8— HEATING, VENTILATING, REFRIGERATION AND AIRCONDITIONING
13.3 Pressure limiting devices shall be connected of the refrigerant at 46.11°C. In no case
between the compressor and the top valve on shall the test pressure be less than 206.7
the discharge side. kPa by gauge.
166
CHAPTER 8— HEATING, VENTILATING, REFRIGERATION AND AIRCONDITIONING
167
CHAPTER 8— HEATING, VENTILATING, REFRIGERATION AND AIRCONDITIONING
168
CHAPTER 8— HEATING, VENTILATING, REFRIGERATION AND AIRCONDITIONING
(2)
(3)
hve = enthalpy of saturated
HP LIQUID vapor at evaporating pressure, kJ/kg.
EXPANSION
VALUC (A
1
h = enthalpy of saturated
(1
(t
liquid at condensing pressure, kJ/kg.
MOTOR
COMPRESSOR LP GAS
Thus hie = enthalpy of saturated
Fig. 81R 2u
liquid at evaporating pressure, kJ/kg.
Figure 8182a
f = sometimes called
“dryness friction” mass in kg of
refrigerant which vaporizes during
Refrigeration Cycle p. 179 throttling per kg circulated.
3)
D
3)
ci) Example:
Ui
p Solution:
enthalpy 187.53—36.05
of liquid at
Condens
ng pres
= 0.2211
sure
18.4 Refrigerant Effect
= hvef + hie (1 — t) = 10
h The refrigerant effect per kilogram of refrigerant
in circulation is given by the formula —
Or
Refrigerating Effect (RE) = (hec— h
)
1
f = _2)Ei2jfi_.
hve hie— eq. 1 where:
Note: The subscripts I and v denotes liquid and vapor, RE = Refrigerating effect per kilogram of
respectively. circulating refrigerant
hec = enthalpy of refrigerant entering the
cooling coil
169
CHAPTER 8— HEATING, VENTILATING, REFRIGERATION AND AIRCONDITIONING
1
h = enthalpy of refrigerant leaving cooling Section 20.0 Energy Conservation for
coil Ventilating, Refrigeration & Air
Conditioning
18.5 Refrigeration CapacityITon of Refrigeration
20.1 To conserve on energy consumption, energy
All Refrigerating Capacities shall be expressed
recovery and saving devices, as recommended
in kilowatts (kw). For 1 Ton of Refrigeration Society of Heating,
by the American
(TR), this would be equal to 3.517 kilowatts
Refrigerating and Air Conditioning Engineers
The work of (ASHRAE), Air Conditioning and Refrigeration
18.6 Work of compression —
effect) to the energy supplied to the compressor. 40 960.7 0.0182 74.59 203.20 0.6825
a)
40 8477 0.0212 - 205.21 0.6950
COP = h—hk=RE 45 847.7 0.0218 - 208.96 0.7078
h d hve
—
50 847.7 0.0224 212.72 0.7196 C’
The ratio of energy 21.1 Considering that the Philippines is one of the
18.8 Energy Efficiency Ratio
signatories in the Montreal Protocol, all
—
170
CHAPTER 8— HEATING, VENTILATING, REFRIGERATION AND AIRCONDITIONING
Table 8.9
Comparative Performance of Refrigerants at 5°C Condensing at 40°C
F 0) 1 -
0
= OW — >
0
Q oa 0 >0) E •
e 0 1)
. E Name of Refrigerant 0 a -
— .
•5 a
-D 0.
z coE CUJ 0>
c W
I- W 0 0 0.0 o°) w
0
718 Water 5° 0.009 0074 846 2370.0 147.0 62.0 0.1355 92.9
717 Ammonia 5° 5.160 15.55 3.01 1088.0 0.243 0.214 0.1456 86.4
114 Dichlorotetrafluoroethane 12.7° 1.062 3.373 3.18 106.2 0.122 1.14 0.1484 84.8
113 Trichlorotrifluoromethane 10.4° 0.188 0.783 4.16 129.5 0.654 5.03 0.1511 83.3
171
CHAPTER 9— FIRE PROTECTION & PREVENTION
Chapter 9
172
CHAPTER 9— FIRE PROTECTION & PREVENTION
Class Ill Commodity is defined as wood, “Sprinkler System Design Curves for Solid
paper, natural fiber cloth, plastic products on Pile, Palletized and Bin Box Storage over 12
wood pallets, products may be contain a ft. (3.7 m), and Shelf Storage 12 ft. (3.7 m) to
limited amount of plastics. Wood dressers 15 ft. (4.6 m) high, shall be in accordance with
with plastic drawer glides, handles, and trim Figure 9-1.1” (6-1.2)
are examples of a commodity with a limited
amount of plastic.
173
CHAPTER 9— FIRE PROTECTION & PREVENTION
Table 9.1.3
Sprinkler Discharge Density Areas of Application
Piling Height gpml ft
2 2 (see Note 1)
ft
Piling Method ft
(See Notes 1 and 2) Ord. Temp. Heads High Temp. Head
1.On Floor
a. Pyramid
b. Other arrangements such that Up to 5 See NFPA 13, Standard for Installation of Sprinkler Systems
no horizontal channels are 5 + to 7 0.24 2,000 2,000
formed 7 + to 8 0.26 2,000 2,000
c. Tires piled on floor on tread 8 + to 10 0.28 2.000 2,000
(See Note 3) 10 + to 12 0.32 2,000 2,000
2. Palletized
On side or tread 9 to 20 See Figure 4—1.2
20 to + 30 0.3 plus high 3,000 3,000
Expansion foam
Notes:
1. Sprinkler discharge densities and areas of application are based on a maximum clearance of 10 ft (3.1 m) between sprinkler defectors and the
maximum available height of storage.
2. The densities and areas provided in the table are based on fire tests using standard response; standard orifice (1/2 in.) and large orifice (1 7/32 in.)
sprinklers. In buildings where “old style” sprinkler heads exist, discharge densities shall be increased by 25%. For use of other types of sprinklers,
consult the authority having jurisdiction.
b. Fire Protection Standard for Storage of Heavy Weight Class. Includes paper board
Rubber Tires. This provision contained in and paper stock having a basis weight [weight
this standard apply to new facilities for tire per 1,000 sq.ft. (93 m.sq.)j of 20 lb. (9.1 kg.) or
storage and when converting existing greater.
facilities to tire storage occupancy.
Medium Weight Class. Includes the broad
c. Fire Protection Standard for the Storage range of papers having basis weight [weight
of Roll Paper. The purpose of this standard per 1,000 sq.ft. (93 m.sq.)] from 10 lb. (4.5 kg.)
is to provide a reasonable degree of to 20 lb (9.1 kg.)
protection for the storage of roll paper when
stored in buildings or structures through Light Weight Class. Includes all papers
installation requirements based upon sound having basis weight [weight per 1,000 sq.ft.
engineer principles and test data. (93 m.sq.)] less than 10 lb (4.5 kg) and
tissues.
Classification of Roll Paper:
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CHAPTER 9— FIRE PROTECTION & PREVENTION
2. The densities and areas provided in spread of fire having a fire resistance rating of
the table are based on fire tests using not less than four hours and having sufficient
response; standard office (1/2 in.) and structural stability under fire conditions to allow
large orifice (17/32 in.) sprinklers. In collapse of construction on either side without
buildings were “oldstyle” sprinkler collapse of wall.
exist, discharge densities shall be
increased by 25%. For used of other Horizontal Channel Any uninterrupted space
—
10 >5 .3/2000 .3/2000 .3/2000 .3/2000 .3/2000 .3/2000 .3/2000 .3)2000 .3)2000
15 <5 .3/2000 .3/2000 .3/2000 .3/2000 .3/2000 .3/2000 .3/2000 .45/2500 .45/2500
15 >5 .3/2000 .3/2000 .3/2000 .3/3000 .3/3500 .3/2000 .3/2500 .45/3000 .45/3000
20 < 5 .3/2000 3/2000 .3/2500 .45/3000 .45/3500 .3/2000 .45(2500 .6/2500 .6/2500
20 >5 .3/2000 .3/2500 .3/3000 .45/3500 .45/4000 .3/2500 .45/3000 .6/3000 .6/3000
25 < 5 .45/2500 .45/3000 .45/3500 .6/2500 .6/3000 .45/3000 .6/3000 .75/2500 .75/2500
NOTE: Densities and/or areas may be interpolated between any 5 ft storage height increment.
SI Units: 1 ft = 0.3048m; 1 gpm/ft
2 = 40.746 (L/min)/m
2
storage can be stored above the floor and still commodity wrapping, cushioning or container.
maintain adequate clearance from structural
members and the required clearance below Storage Aids This term designates
—
similar to wood, cloth or paper and which building used principally for the storage of
commodities.
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CHAPTER 9— FIRE PROTECTION & PREVENTION
packaging, either of which will contribute fuel to Should Indicates a recommendation or that
—
packaging which will neither ignite nor support protection purpose, is an integrated system of
combustion. one or more water supplies for fire use,
underground and overhead piping designed in
The word SHALL is intended to indicate accordance with fire protection engineering
requirements. standards. The portion of the sprinkler system
above ground is a network of specially sized or
The words IT IS RECOMMENDED indicate hydraulically designed piping installed in building
advisory provisions. APPROVED refers to structure or area, generally overhead, and to
approval by the authority having jurisdiction. which sprinklers are attached in a systematic
pattern. The valve controlling each system riser
Approved. Acceptable to the “Authority having is located in the system riser or its supply piping.
jurisdiction”. Each sprinkler system includes a device for
actuating alarm when the system is in operation.
Authority Having Jurisdiction. The “authority The system is usually activated by heat from a
having jurisdiction” is the organization, office or fire and discharges water over the fire area.
individual responsible for approving equipment,
an installation or procedure. Warehouse Any building or area within a
—
Class B Fire — Fire in flammable liquids and a. Type I Storage. Type I storage is that in
gases. which combustible commodities or non-
combustible commodities involving
Class C Fire Fire— involving energized combustible package or storage aids are
electrical equipment. stored over 4,550 mm but not more than
6,400 mm high in solid piles or over 3,650
Class D Fire Fire involving combustible
—
mm but not more than 6,400 mm high in
metals, such as magnesium, sodium, potassium, piles that contain horizontal channels. Minor
titanium and other similar metals. quantities of commodities of hazard greater
than ordinary combustibles may be included
Dry Stand Pipe a type of stand pipe system in
—
without affecting this general classification.
which the pipes are not normally filled with
water. Water is introduced into the system thru b. Type II Storage. Type II storage is that in
Fire Service connections when needed. which combustible commodities or non-
combustible commodities involving
Fire Service An organization or a component
—
combustible packaging or storage aids are
of the Philippine National Police Fire Department stored not over 4,500 mm high in solid piles
personnel in-charge with the mission of fire or not over 3,650 mm high in piles that
prevention, fire protection. contain horizontal channels.
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CHAPTER 9- FIRE PROTECTION & PREVENTION
c. Type Ill Storage. Type II storage is that in Section of the warehouse occupied as boiler
which the stored commodities packaging room, engine room, or garage shall be cut
and storage aids are non-combustible or off from other sections of the warehouse by
contain only a small concentration of construction having a fire resistance of at
combustibles which are incapable of least two hours.
producing a fire that would cause
appreciable damage to the commodities Adequate access shall be provided to all
stored or to non-combustible wall, floor or portions of the premises for fire fighting
roof construction. Ordinary combustible purposes. Frangible wall sections for fire
commodities in completely sealed non- department or other emergency access or
combustible containers may qualify in this exit should be considered where doors are
classification subject to the authority having not practical.
jurisdiction. General commodity storage that
is subject to frequent changing and storage b. Areas. Fire areas of warehouses should be
of combustible packaging and storage aids limited to maintain the total value of the
is excluded from this category. commodity within reasonable limits yet not
be too restrictive for low value commodities.
2.4 Building Arrangement Conversely, high value and vital
commodities. Should be restricted to smaller
a. Construction. One-storey buildings without areas than for average value commodities
basement storage areas are preferable for such as found in the usual general
warehouses because of greater efficiency warehouse. The combustibility of the
for fire fighting and salvage operations. commodity and its packaging or storage aids
Long narrow buildings provide greater ease should be taken into account. Other
in protection and fire fighting than large considerations are the difficulty encountered
square buildings. Multi-storey buildings may in fire fighting and salvage operations in
be subject to the spread of fire from lower to large undivided areas.
upper floors and water used on upper floors
may cause damage on lower floors. Type I and Type II Storage. When
protected in accordance with this standard,
Newly-constructed warehouses over one 4,645 m 2 is considered the maximum area
storey in height should be of not less than for average value commodities enclosed by
three-hour fire-resistive construction. exterior walls or combination of exterior
walls and fire walls. A multi-storey building
Fire wall construction shall be parapet at having three-hour fire-resistive construction
least 910 mm above the building roof, shall be considered as having each floor a
except the parapet may be omitted where separate fire area. A multi-storey building of
the wall fits tightly to the underside of a fire- less than three-hour fire resistance at each
resistive roof deck. In buildings having floor shall be considered to be one fire area
combustible exterior walls, intersecting fire with the floor area per level being
walls shall extend at least 1,850 mm in total cumulative.
length. Fire walls should preferably be
without openings, but if openings are Type Ill Storage. Warehouses constructed
necessary they shall be provided with self- and protected in accordance with this
closing or automatic fire doors on each side standard may be of any reasonable area.
of the wall. Such doors shall be suitable for
openings in the particular fire wall. c. Ventilation. Consideration should be given
to the provision of roof vents and curtain
A wall or partition separating the warehouse boards, particularly in large one-storey
from other occupancy shall have fire warehouses where distance to exterior wall
resistance rating sufficient to protect the openings makes it difficult to place hose
warehouse from the fire exposure of the streams in service.
other occupancy. Door openings shall be
equipped with automatic closing fire doors d. Protection of Stairways and Shafts.
appropriate for the fire resistance rating of Stairways and other vertical shafts shall be
the wall or partition. enclosed with fire-resistive construction or
sealed at each floor level with construction
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CHAPTER 9- FIRE PROTECTION & PREVENTION
having the same fire resistance rating as the means of an exterior balcony, the
floor. door assembly to the stair shall
have a 1-1/2-hour fire protection
Where stairways are required for the exit of rating and shall be self-closing or
occupants, such stairways and doors in shall be automatic-closing by
interior partitions enclosing stairways shall actuation of a smoke detector.
be adequately protected. Openings adjacent to such exterior
balconies shall be protected as
e. Stairways and Shaft of High Rise required and as follows:
Buildings Shall Be Smoke Proof
Enclosures. Smoke proof enclosures shall 2. Every vestibule shall have a
be a stair enclosure so designed that the minimum net area of 16 sq. ft. (1.5
movement into the smoke proof enclosure of sq.m.) of opening in an exterior
the product of combustion produced by a fire court, yard or public space at least
occurring in any part of the building shall be 20 ft. (6.1 m) in width.
limited and/or eliminated.
3. Every vestibule shall have a
The smoke proof enclosure may be minimum dimension not less than
accomplished by using natural ventilation, the required width of the corridor
by using mechanical ventilation leading to it and a minimum
incorporating a vestibule or by pressurizing dimension of 72 in. (183 cm) in the
the stair enclosure. direction of travel.
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CHAPTER 9— FIRE PROTECTION & PREVENTION
located not more than 6 in. (15.2 shall also be initiated by the following, if
cm) down from the top of the trap provided.
and shall be entirely within the
smoke trap area floors, when in the 1. Water flow signal from a complete
open position, shall not obstruct automatic sprinkler system.
duct opening. Duct opening may be
provided with controlling dampers if 2. General evacuation alarm system.
needed to meet the design
requirements but are not otherwise j. Standby Power. An approved self-
required. contained generator set to operator
whenever there is a loss of power in a
4. The vestibule ceiling shall be at normal house current shall provide standby
least 20 in. (50.8cm) higher than the Power for mechanical ventilation. The
door opening into the vestibule to generator shall be in separate room having
serve as a smoke and heat trap and a minimum- 1 hour fire resistive occupancy
to provide an upward moving air separation and shall have minimum fuel
column. The height may be supply adequate to operate the equipment
decreased when justified by for 2 hours.
engineering design and field testing.
k. Testing. Before the mechanical equipment
5. The stair shall be provided with a is accepted by the authority having
damper relief opening at the top and jurisdiction, it shall be tested to confirm that
supplied mechanically with sufficient the mechanical equipment is operating in
air to discharge a minimum of 2500 compliance with these requirements.
cu. Ft/mm. (70.8 cu rn/mm) through
the relief opening column in the stair Emergency Lighting. The stair shaft and
relative to atmosphere with all doors vestibule shall be provided with emergency
closed and a minimum of 0.10 inch lighting.
water column (25 Pa) difference
between the stair and the vestibule. m. Exposure Protection. Adequate protection
against exposure shall be provided where
h. Stair Pressurization. Smoke proof the warehouse or its contents are subject to
enclosures by stair pressurization shall damage from external fire. Depending upon
comply with all of the following: the severity of the exposure, such protection
should consist of parapet masonry walls
1. The building shall be protected without openings, wire glass in metal framed
throughout by an approved windows and/or open sprinklers.
supervised automatic sprinkler
system. n. Drainage of Floors. Upper floors of multi-
storied buildings should be made water tight
2. There shall be an engineered and provided with floor drainage facilities.
system to pressurize the air
enclosure capable of developing o. Piles Containing Horizontal Channels
0.05 in. (12.5 Pa) in addition to the
maximum anticipated stack p. Type I and Type II Storage. Horizontal
pressure relative to other parts of channels formed by rack arrangement
the building measured with all the should be suitably fire-stopped by means of
enclosure doors closed. barrier at intervals of 7,620 mm unless
additional automatic sprinklers are provided
Activation of Mechanical Ventilation at intermediate levels to protect the storage.
System.
Horizontal channels of palletized storage
For both mechanical and pressurized stair should be perpendicular to the aisle. No
enclosure systems, the activation of the part of such horizontal channels shall be
systems shall be initiated by smoke more than 7,620 mm from an aisle
detectors and by manual controls accessible measured along the length of the channel. It
to the fire department. The required system
179
CHAPTER 9— FIRE PROTECTION & PREVENTION
180
CHAPTER 9— FIRE PROTECTION & PREVENTION
181
CHAPTER 9— FIRE PROTECTION & PREVENTION
182
CHAPTER 9— FIRE PROTECTION & PREVENTION
183
CHAPTER 9— FIRE PROTECTION & PREVENTION
Density (Llmin) / m
- 2
4.1 6.1 8.1 10.2 12.2 14.3 16.3
2.0
645
DC
a 372
4000
a
0
C
oS 0
5)
0.
0 5)
a
00) 0
279 5)
C 3000 I
a C
I
(0)
a
0 232 C,)
CU
5) 2500 0
‘5
5)
00
186
00 I 139
0.10 0.15 0.20 0.25 0.30 0.35 0.40
0.05
Density gpmlsq ft
-
184
CHAPTER 9— FIRE PROTECTION & PREVENTION
185
CHAPTER 9— FIRE PROTECTION & PREVENTION
186
CHAPTER 9- FIRE PROTECTION & PREVENTION
187
CHAPTER 9- FIRE PROTECTION & PREVENTION
378 51 51 38 51 64 1 —38 51
946 89 76 51 64 89 1 —65 76
1,892 127 127 76 127 127 2—65 102
2,839 152 152 102 150 152 3—65 150
3,785 203 152 102 203 203 4—65 150
5,677 203 203 152 203 203 6—65 203
7,570 254 254 152 254 203 6—65 303
9,462 254 254 152 254 203 8—65 254
11,355 305 305 203 305 203 12—65 254
13,247 305 305 203 305 254 12—65 305
15,140 356 305 203 356 254 15—65 305
Bars or more and shall have the following every part of the exterior of each building not
features standard equipment. covered by standpipe protection for every
part of each building by the use of lengths of
b. There are two types of standard fire pump hose normally attached to the hydrants.
used for the protection service, the There shall be sufficient hydrants to
centrifugal and the vertical turbine type, concentrate the required fire flow above any
either horizontal or vertical mounted are important building protected. An adequate
permitted to obtain water on positive suction hose houses shall be placed nearby the
head only. The vertical turbine type is hydrants with standards accessories as
practically suitable for fire pump service follows:
when the water is located below ground
where it would be difficult to install any other 2 — Approved adjustable spray-solid
type of pump below the minimum water stream nozzles equipped with
level. shut-off for each size of hose 65
mm.
Diesel engine drive when used to drive
either centrifugal or vertical turbine fire pump 1 — Fire Axe with brackets
shall be specifically listed for fire pump
service by the testing laboratories. Engines 1 — Hydrants Wrench
shall be acceptable for horse power rating
with listed controllers and standard 4 — Coupling spanners for each sized
accessories, such as angle gear drive, hose provided, 65 mm
governor, over speed shutdown devices,
tachometer, oil pressure gage, temperature 2 — Hose Coupling gaskets for each
gage, instrument panel, factory wiring, size of hose, 65 mm
electrical starter, two (2)sets of batteries with
battery charger, engine cooling exchanger 3.6 Dry Stand Pipe and Hose Systems
system, fuel tank, exhaust muffler and
others. a. Standpipe systems are none of the best
internal means for extinguishing fires in
c. Pressure Maintenance (jockey or make buildings and structures. Even in buildings
up) Pumps. Jockey pumps shall have rated equipped with automatic sprinkler systems,
capacities not less than any normal leakage standpipe is necessary. Standpipes are
rate they shall have discharge pressure required in places such as the upper storey
sufficient to maintain the desired fire of high buildings or large areas, low height
protection system pressure. buildings, and in other structures where
construction, size of other features limit the
3.5 Outside Protection use of hose streams from the exterior.
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CHAPTER 9- FIRE PROTECTION & PREVENTION
Class II — For use primarily by the Minimum water supply for Class
buildings occupants until the arrival II service shall be 380 Lpm at 30
of the fire department 38 mm hose. minutes.
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CHAPTER 9— FIRE PROTECTION & PREVENTION
(c) Throughout floors below the 1. Class A Fires. Are fires in ordinary
street floor having 232.5 sq. m combustible materials such as
when used for the space, wood, cloth, paper, rubber and
storage or handling of many plastics.
combustible goods and
Merchandise. Extinguishers for protection of Class
A hazards shall be selected from the
7. Business Occupancies. All following: water types, foam, loaded
business occupancy buildings over stream, and multi-purpose dry
15 meters high shall be provided chemicals. The maximum travel
throughout with automatic sprinkler distance to such extinguishers shall
protection. not exceed 22.8 m.
190
CHAPTER 9— FIRE PROTECTION & PREVENTION
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CHAPTER 9— FIRE PROTECTION & PREVENTION
6. Adequate clearance space between All electrical equipment and installation shall
storage piles and any highways and conform to the provisions of the Philippine
railroads. Electrical Code.
4.5 Material Piling. Materials shall be stored in unit All heating equipment shall conform with
piles as low in height and small area as in established fire prevention standards.
consistent with good practice for the material Salamanders, braziers, portable heaters or other
stored. The maximum height will be determined open fires shall not be used.
by the base of pile and type of packaging,
stability of the material and limit of the effective Smoking shall be strictly prohibited in any
reach of hose streams. location where the practice might cause fire.
“No Smoking” signs shall be posted throughout
Aisles shall be maintained between individual the storage area except in specific locations
piles, between piles and buildings and the designated as safe for smoking purposes.
boundary line of the storage site. Sufficient
driveways, having a width of at least 4,500 mm 4.9 Storage and Use of Motor Vehicles Using
shall be provided to permit the travel of fire Gasoline or Liquefied Petroleum Gas as Fuel.
equipment to all portions of the storage area. Vehicles should be garaged in a separate
Aisles shall be not less than 3,000 mm wide to detached building. Storage and handling of fuel
reduce danger of spread of fire from pile to pile shall conform to approved standards of
and to permit ready access for fire fighting, Flammable and Combustible liquids and
emergency removal of materials or for salvage approved standards for the storage and
purposes. Extra combustible materials will Handling of Liquefied Petroleum Gases. Repair
require wide aisles and roads dependent upon operations shall be conducted outside the yard
the height of the pile and the degree of unless separate masonry walled building is
combustibility. For extra combustible materials, provided. If vehicles are to be greased,
the width of aisles should be equal to the height repaired, painted or otherwise serviced, such
of the pile but not less than 3,000 mm. work shall be conducted in conformance with
standards as approved by the authority having
4.6 Fences. The entire property shall be jurisdiction.
surrounded in the fence or other suitable means
to prevent access of any unauthorized persons. Tarpaulins, used for protection of storage
against the weather, shall be of approved flame
4.7 Buildings. Buildings in outside yards shall be proof fabric.
located with as much clear space to open yard
storage as is practicable but shall be not less Coal-fired steam locomotives shall not be
than 4,500 mm from open yard piling unless allowed to enter the yard where combustible
buildings have blank exterior masonry walls. material is stored unless the smokestack is
Buildings of wood frame construction or protected by a spark arrester and the ash pan is
containing hazardous operations shall be at protected by screens to prevent hot coals from
least 15.2 m from the nearest storage pile; and escaping.
explosion vents, blower outlets, etc., not be
directed toward the yard storage. Oil-fired steam locomotives and Diesel
locomotives from which glowing particles or
4.8 Yard Maintenance and Operations. The entire carbon are emitted from the exhaust stacks shall
storage site shall be kept free from accumulation not be permitted in the yard.
of unnecessary combustible materials. Woods
and grass shall be kept down and regular 4.10 Fire Protection. Provisions shall be made by
procedure provided for the periodic clean-up of some suitable means for promptly notifying the
the entire area. public fire department or private fire brigade in
case of fire or other emergency.
Adequate lighting shall be provided to allow
supervision of all parts of the storage area at Provisions shall be made to permit direction of
night. an adequate number of hose streams on any
pile or portion of the storage area that may be
involved in fire. Unless adequate protection is
provided by a Municipal fire department,
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CHAPTER 9— FIRE PROTECTION & PREVENTION
sufficient hose and other equipment shall be a. Regular fire safety audit in every workplace.
kept on hand at the storage property, suitably
housed and provision be made for trained b. Seasonal fire hazard review, like fire
personnel constantly available to put it into prevention month assessment.
operation. Monitor nozzles shall be provided at
strategic points where large quantities of highly c. Fire prevention awareness shall be
combustible materials are stored. promoted through pamphlets and posters.
Hydrants and all fire fighting equipment shall be d. Employers shall teach workers to operates
accessible for use at all times. No temporary machines properly and to report any
storage shall be allowed to obstruct access to problems that could cause fire.
fire fighting equipment.
e. Workers shall be empowered to do fire
4.11 Watch Service. Standard watch service shall hazard inspection near machines in their
be provided and continuously throughout the workplace to supplement supervisor, safety
yard and storage area at all times while the yard audit.
is otherwise unoccupied. It is required that there
be some suitable means of supervising the f. A clean workplace program following 5s
watchman’s activities to be sure that he makes standard and emphases (sorting, sweeping,
his required rounds at regular intervals. standardizing, and systemizing) and self-
discipline.
Attention is directed to the value of strategically
placed watch towers in large yards where a 7.2 Fire prevention is a term for the many safety
watchman, stationed at a point of vantage, can measures used to keep harmful fires from
keep the entire property under observation. starting this is being carried out by several
Such towers shall be connected to the fire alarm programs in fire safety, like
system so that prompt notification of fire may be
given. a. Laws and specifications.
Section 5.0 Anti-Pollution for Standards b. Inspection of buildings and others company
for Indoor and Outdoor General Storage properties.
193
CHAPTER 10- PUMPS
Chapter 10
PUMPS
194
CHAPTER 10 — PUMPS
c. Suitable air valve to take out or caused it to move up thru the piping and out of
replenish air in tank should be installed the nozzles or opening.
on top of tank.
2.4 Hydrodynamics is a general term, and is
d. A tank should be designed for maximum generally associated with the science of the
total dynamic pressure required force exerted by water in motion, such as driving
multiplied by two to provide for water a turbine connected to an electric generator.
hammer. Factor of safety should not be
less than five. 2.5 Atmospheric Pressure is due to the weight of
the atmosphere on the earth. At sea level the
e. For tanks of 3785 liters or more a atmospheric pressure is 14.7 PSI, or 29.9
separate air compressor should be inches of Mercury column (Hg), which is
installed to replenish air absorbed by the commonly designated as one atmosphere.
water. Atmospheric pressure diminishes with elevator
above sea level. It is atmospheric pressure on
f. For figuring equipment, pipes fittings an open body of water that forces the water up
and valves, the right pressure ratings in pump suction pipe in those cases when a
should correspond to total dynamic pump takes suction under lift. (A pump should
head multiplied by two to cover water always take a suction under water pressure at
hammer effect. atmospheric pressure).
2.2 Hydrostatics is the science of water at rest. A No matter how many square inches are covered
good example is a gravity tank filled with water by a column of water one foot high, the pressure
and supplying water to closed valve. Until the is still 0.433 pounds per square inch or 0.433
valve is opens, the water is at rest, but its weight PSI. 2.31 is the reciprocal of 0.433.
has potential energy and exerts a definite force,
or static rressure against the closed valve. Pressure is force applied to liquids, or force
developed by the weight of the liquids. Pressure
2.3 Hydrokinetics is a science of water in motion. is also called “head”. Pressure is measured in
When the valve in the preceding example two ways:
opens, the potential energy of static pressure
becomes kinetic energy. The weight of water a. The number of feet the pressure will
force a column of liquid up to rest. This
195
____
is called head in feet, and designated as (or in meters) of mercury (Hg). Differential
h in feet. (closed) manometers, may be used for
measuring differences in pressure, such as the
b. The number of pounds of force exerted difference between two points in a pipe or
on one square inch. This is called between the total and normal pressure at the
pounds per square inch and designed same point in pipe.
as p (PSI) and/or kilogram per square
).
meter (kg/rn
2 2.12 Pilot Tube. (named for its inventor Pilot) is
used to measure the pressure of water
discharging from a nozzle or flowing in a pipe by
having its open end in the water and the other
Bourdon tube -Zero position end connected to a gauge or manometer. The
tube is generally about one-sixteenth inch in
diameter, bent at right angles, and mounted with
a gauge or manometer connected to the long
end. The short end is held by hand in a hose
stream, nozzle or flowing water. (See figure
10.2.1; 10.2.2; 10.2.3; and 10.2.4).
The two pressure measurements for water 2.14 Capacity is the rate of flow of liquid measure
are related in this way: per unit of time, usually gallons per minute
(GPM) or liters er minute (LPM).
P (in PSI) = 0.433 h (in feet)
196
CHAPTER 10— PUMPS
to datum, plus the velocity head at the point of Where: g is the acceleration due
gage attachment. to gravity = 32.17 feet
per second square.
2.17 Velocity Head (Hv) is figured from the average
velocity (v) obtained by dividing the discharge in
cubic feet per second (cfs) or cubic meter hv = V
2
second (cms) by the actual area of the pipe 2g
cross section in square feet or square meter and
determined at the point of the gage connection. and V is average velocity in the
It is expressed by the formula: pipe in feet per second.
0 .j:0t
2.19 Total Head is the measure of the energy
increase per pound imparted to the liquid by the
pump and is therefore the algebraic difference
between the total discharge head and the total
suction lift exists, is the sum of the total
Fig. 10-3 discharge head and total suction lift; and when
Differential Manometer (U-Tube) for Measuring velocity suction head exists, the total head is the total
pressure by means of the difference between total pressure
(from Pitot Tube) normal pressure (from Piezometer)
discharge head minus the total suction head.
197
__________________
column pipe used to connect the bowls to the They are available as horizontal o
discharge head on which the pump driver is vertical pumps, single or multi-stage
mounted. for wide flow ranges.
2.28 Submersible Pump. A vertical turbine pump Mixed-flow centrifugals pumps are
with the pump and motor closed coupled and Mixed-Flow ideal for low head large-capacity
designed to be installed underground, as in the ] applications. Usually vertical, they
have a single-inlet impeller. Some
case of the deepwell pump.
horizontal units are built.
2.29 Aquifer. An underground formation that Axial-flow units, often called
contains sufficient saturated permeable material Axial-Flow propeller pumps, develop most of
to yield significant quantities of water. their head by lifting action of vanes,
are usually vertical, and best suited
2.30 Aquifer Performance Analysis. A test for low heads, large capacities.
designed to determine the amount of
underground water available in a given field and For clear liquids, turbine pumps,
Turbine or either horizontal or vertical, fill a
proper well spacing to avoid interference in that Regenerative need between other centrifugal and
field. Basically, test results provide information usual rotary designs. They are low-
concerning transmissibility and storage to-medium-capacity high head.
coefficient (available volume of water) of the
aquifer. Gear pumps consist of two or more
Gear Vane gears (spur, single-or double-helical
2.31 Wet Pit. A timber, concrete, or masonry teeth) while vane pumps have a
enclosure having a screened inlet kept partially series of vanes, blades or buckets
filled with water by an open body of water such turned by a single rotor. This rotary
class also includes lobe or shuttle-
as pond, lake, or streams.
block designs.
2.32 Ground Water. That water which is available Cam and piston rotaries, like most
from a well, driven into water-bearing Cam and types in this class, are positive-
subsurface strata (aquifer). Piston displacement units, giving steady
discharge flow along with screw-
2.33 Static Water Level. The level with respect to type pumps, and related designs,
the pump, of the body of water from which it they handle a wide range of non-
takes suction when the pump is not in operation. abrasive viscous liquids.
2.34 Pumping Water Level. The level, with respect Old standbys for years, direct
Direct-Acting acting pumps now are available in
to the pump, of the body of water from which it many designs for handling cold or
takes suction, when the pump is in operation. ] hot water, oil, and a wide range of
industrial liquids of many types.
2.35 Draw-Down. The vertical difference between
the pumping water level and the static water Power pumps are driven from
level. Power outside through a crankshaft or
other device. Capacities range
from very low to medium flows, at
Section 3.0 Pumps pressure up to 15,000 psi, (1033.5
bars), or higher.
THESE QUICK GUIDES TO THE WORLD OF PUMPS Crank-and-flywheel pumps are one
SHOW THE MAJOR CLASSES AND TYPES IN USE Crank- form of reciprocating power pump,
TODAY: Flywheel so designated to distinguish them
from power pumps using, for
example, an eccentric as drive
Volute The majority of centrifugal pumps mechanism.
built today are the volute type.
198
CHAPTER 10— PUMPS
A. CENTRIFUGAL:
1. AXIAL FLOW
Self-printing
3. Perpheral — — — —
Non-printing
Jet (eductor)
Gas lift
B. SPECIAL EFFECTS
Hydraulic Ram
Electromagnetic
simplex
C. RECIPROCATING: 1. Piston
Plunger
tiiplex
multiplex
2 Diaphragm
D. ROTARY
199
CHAPTER 10— PUMPS
pressure energy either by passing the fluid thru indicates the mounting requirements (most
a volute casing or thru diffuser vanes. likely floor space). A further classification is
applicable for turbo machines, particularly
After the conversion is accomplished, the fluid is where the casing halves divide for
discharged from the machine. disassembly.
By Mounting Generally describes the
—
When the kinetic energy is converted to design method of mounting the pump and
pressure energy by means of the volute shape applies but not necessarily always specified
of the casing, the pumps are called volute for all pump types.
centrifugal pumps. When the conversion of By Operation -Basically is the description
kinetic energy to pressure energy occurs in the of the design duty of the stand by pump
passage of the fluid thru stationary diffusers like for the example, air pump, source pump,
vanes, the pumps are called diffuser centrifugal stand by pump, auxiliary pump, etc. But this
pumps. does not necessarily follow that the use of
such a pump is restricted to the specified
The radial type of impeller is characterized by operation.
rather long narrow passages for the water. The By Liquid Handled This specific
—
ratio of outside impeller diameter D2 to impeller description indicates that the pump can
eye diameter Dl is approximately 2. handle a particular type or types of fluid or
product like chemicals and other corrosive
The Francis type of impeller is characterized by liquids.
wider passages for the water and the ratio of D2 By Material This indicate the type of the
—
this type of impeller has no guidance for the flow are of sufficient importance to warrant a
of water, it cannot operate with suction lift. The classification of their own, representing the
impeller or propeller is generally immersed in the type of pump with integral electric motor,
liquid. which can be immersed in the product being
handled. They can be subdivided into
a. Classification of Centrifugal Pumps various categories according to intended
duty, for example deepwell, borehole, etc.
Centrifugal pumps can be classified, as follows; and by the form of canned motor.
200
CHAPTER 10— PUMPS
201
CHAPTER 10— PUMPS
Law al Qi = Capacity
Hi = head at Ni RPM or with impeller
= Ni Diameter
2
Q N Dl
Q2 = Capacity
Law a2 H2 = head at N2 RPM or with impeller
Diameter
= __Ni D2
H
2 2
N
Law a3 Law al applies to the Centrifugal, Angle Flow,
Propeller, Peripheral, Rotary and Reciprocating
_Yi = __Ni pumps.
2
KW 2
N
Law a2 and a3 apply to Centrifugal, Angle Flow, Mixed
b. At constant impeller speed Flow, Propeller and Peripheral pumps.
202
CHAPTER 10— PUMPS
Parallel and Series Operation of Centrifugal Pumps shape between the screw
threads and is displaced axially
Pumps are installed in parallel to satisfy variable as the rotor threads mesh.
pumping requirements to maintain pump operation at
peak efficiency and optimum power consumption. With (d) Vane Pumps. This type consists
this installation program plant shutdown are easily of one rotor in a casing machined
scheduled without disrupting critical operations. eccentrically to the drive shaft. The
rotor is fitted with a series of vanes,
Similarly, multiple pumps in series may be used when blades or buckets which follow the
liquid must be delivered at high heads. bore of the casing thereby
displacing liquid with each
3.3 Rotary Pumps. A rotary pump is a positive revolution of the drive shaft. Vane
displacement pump consisting of a fixed casing pumps may have swinging vanes or
containing gears, cams, screws, vanes, sliding vanes.
plungers or similar elements actuated by
rotation of the drive shaft. The rotary pump combines the constant
discharge characteristic of the centrifugal type
a. Types with the positive discharge characteristic of the
reciprocating pump. The flow from a
1. Cam and Piston Pumps. This type reciprocating pump is pulsating whereas the
consists of an eccentrically bored flow from many rotary types of pump is constant.
cam, rotated by a shaft concentric in The positive discharge characteristic including
a cylindrically bored casing, with an reciprocating pump prevents the operation of
abutment or follower so arranged these pumps against a closed discharge unless
that with each rotation of the drive an automatic unloader is provided to bypass the
shaft a positive quantity of liquid is discharge with the suction well. Rotary pumps
displaced from the space between are capable of handling only a clean solution
the cam and follow and the pump essentially free of solids and particularly
casing. adopted to handling liquids of high viscosities,
such as heavy fuel oil, paint, etc.
2. Gear Pumps. This type consists of
two or more gears, operating in 3.4 Reciprocating Pumps. A reciprocating pump is
closely fitted casing so arranged a positive displacement unit wherein the
that when the gear teeth unmeet on pumping action is accomplished by the forward
one side liquids fills the space and backward movement of a piston or plunger
between the gear teeth and is inside a cylinder usually provided with valves.
carried around in the tooth space to Piston types are used for low pressure light duty
the opposite side and displaced as or intermittent service. Less expensive than the
the teeth mesh again. There are plunger design, but cannot handle gritty liquids.
two types of gear pumps: Plunger types are used for high pressure heavy
duty or continuous service.
(a) External gear pumps have all
the gear rotors cut externally. Suitable for gritty and foreign material service,
The gears maybe spur, single and more expensive than the piston design.
helical or double helical.
a. Types of Reciprocating Pumps
(b) Internal gear pumps have one
rotor with internally cut gear 1. Direct Acting Steam Pumps. This
teeth meshing with an externally type has a steam cylinder with no
cut gear idler. Pumps of this lap on valves, a water cylinder and
type are made with or without a a common piston rod. As there is
crescent shaped partition. no lap, the steam is admitted
throughout the length of the stroke,
(c) Screw Pumps. This type hence the pressure volume diagram
consists of one, two or three of the steam end is rectangle.
screw rotors so arranged that as Consequently, the water end flow
the rotors turn liquid fills the diagram will also be a rectangle with
203
CHAPTER 10— PUMPS
40
1. Air Chamber. Its function is to
1301 smoothen the flow due to the nature
of flow of the liquid from such type
hr of pump. The size of air chamber
required depends on the type of
90
pump, and generally on the
80
pressure and length of pipe line. Air
70
chamber can be placed either on
the suction side or discharge side of
60
the piping installation.
50
RATED SPEED
3. Foot Valve and Strainer. These
should also be installed at the end
Fig. 10.9 Chart showing effect of speed change on of the suction pipe. The foot-valve
centrifugal pump performance. should be of a size at least equal to
the size of the suction pipe. The
the discharge flow constant clear area of the strainer should be
throughout the length of the stroke at least three times the area of the
and going down to zero value at the suction pipe in order to minimize
instant or reversal of the piston at head loss at this point.
the end of each stroke.
c. Head, Capacity, Efficiency. The total head
2. Crank and Flywheel as defined for centrifugal pumps also
Reciprocating Pump. This type is applies to reciprocating pumps. It is general
driven by compound, cross- practice of manufacturers of reciprocating
compound, or triple-expans ion pumps to state capacities in terms of piston
steam engines. In large sizes such or plunger displacement without deduction
units are known as pumping for the piston rod area or slippage.
engines. Volumetric efficiency is defined as:
204
CHAPTER 10— PUMPS
205
CHAPTER 10— PUMPS
The water horsepower is: There are several metric methods of specifying
pressure. The most basic is the newton per
WHP = QWH When Q is expressed in ). However, it is convenient
square meter (N1m
2
33 000 gpm to use the term pascal (Pa) which represent one
Newton per square meter; by doing this pascal
or is associated with pressure and not with stress.
Segments of the fluid power industry prefer the
WHP QH for water at standard term bar, which is equal to 100 000 pascals.
3960 temperature i.e., one gallon The following relationship can be used for
of water weighs 8.334 lbs. converting to metric:
For liquids other than water or for water at other 1 bar 100 000 Pa
=
temperatures than the standard: 100 000 N1m
= 2
= 14.5 psi
WHP = Q x H x Sp. Gr. 1 inch mercury (at 60°F) = 0.034 bars
3 960
Other manufacturers of fluids power equipment
Where specific gravity of the liquid considered at prefer to express gauge pressure in units of
the corresponding temperature. kg!cm2. For basis of comparison
When pressure, expressed in psi, is considered
instead of head, H, in feet, for water H 2.31 P 1 psi = 0.07045 kgcm
2
for standard conditions.
Customarily, fluid flow has been expressed as
WHP = Q x 2.31 P = QP gallons per minute for liquids and cubic feet per
3 960 1 714 minute for gases. For liquid in metric units,
cubic meter per minute or liters per minute are
When pumping any liquid having a specific usable quantities. The following relationships
gravity against a pressure (P) in psi, the WHP represent relative magnitudes.
equation becomes:
1 gpm = 3.785 liters/mm. = 0.003785 m
/min.
3
206
CHAPTER 10— PUMPS
= 0.7ft PxlO
Pressure head = 30 psi x 2.31 Power = Qx sp. Gr. x sp. Gr.
= 69.3 ft. 6130.25
Elevation = 300 ft = Q x P x 10
Head Loss = lOft 6130.25
*Total head of the pump = pressure head + velocity Example 2:
head + elevation + head loss (if any)
If the pump in example 1 is working against a pressure
= 69.3 + 0.7 + 300 + 10 of 11.6 kg/cm indicated by a gage installed at the
= 380 ft discharge side approximately 1 meter from the pump,
how much power is required?
Energy of pump = 380 ft x 49.5 cfs x 62.4 lbs/cu.ft
550 fps Solution:
= 84 091.90x(11.6x 10)
Whp = QxH Q = 49.5 cfsx448.83 6130.25
3960 = 22 217.14 gpm
= 1591.2kw
207
CHAPTER 10- PUMPS
5.3 Summary of Pump Data. The following table rechecked periodically. To facilitate accurate
10.5.3(a) indicates the minimum recommended field alignment, most manufacturers either do
pipe sizes for the following pump with rated not dowel the pumps or drivers on the base
capacities: plate before shipment, or at most dowel the
pump only.
TabJe 10.5.3(a) Summary of Pump Data
After the pump and driver unit has been placed
Minimum Pipe Sizes (Nominal) on the foundation the coupling halves should be
Relief Water The coupling should not be
disconnected.
Pump
Rating
Suction Discharge Relief Valve Valve Meter reconnected until the alignment operations have
gpmL/min in.* (mm) in. (mm) in. (mm) Discharge Device been completed.
in. (mm) in.
34
25
(95) 1 (25) 1 (25) 3/4 (19) 1 (25) A flexible coupling should not be used to
50(189) 1 1/2 (38) 1 1/4(32) 1 1/4(32) 1 1/2(38) 2(50) compensate for misalignment of the pump and
100 (379) 2 (50) 2 (50) 1 1/2 (38) 2 (50) driver shafts. The purpose of the coupling is to
(65)
150 (568) 2 1/2 (65) 2 1/2 (65) 2 (50) 2 1/2 (65) 3 (75) compensate for temperature changes and to
200 (757) 3 (75) 3 (75) 2 (50) 2 1/2 (65) 3 (75) permit end movement of the shafts without
interference with each other while transmitting
250 (946) 3 1/2 (89) 3 (75) 2 (50) 2 1/2 (65)
(89) power from the driver to the pump.
300(1136) 4(100) 4(100) 21/2(65) 31/2(89) 82
There are two forms of misalignment between
400 (1514) 4 (100) 4 (100) 3 (75) 5 (127) 4 (100)
450 (1703) 5 (127) 5 (127) 3 (75) 5 (127) 4 (100) the pump shaft and the driver shaft, as follows:
500 (1892) 5 (127) 5 (127) 3 (75) 5 (127) 5 (127)
a. Angular misalignment — shafts with axes
750 (2839) 6 (150) 6 (150) 4 (100) 6 (150) 5 (127)
1000 (3785) 6 (150) 6 (150) 4 (100) 6 (150) 5 (127) concentric but not parallel.
1250 (4731) 8 (200) 8 (200) 6 (150) 8 (200) 6 (150)
1500 (5677) 8 (200) 8 (200) 6 (150) 8 (200) 8 (200) b. Parallel misalignment — shafts with axes
2000 (7570) 10 (250) 10 (250) 6 (150) 10 (250) 8 (200)
parallel but not concentric.
2500 (9462) 10 (250) 10 (250) 6 (150) 10 (250) 8 (200)
3000 (11355) 12 (300) 12 (300) 8 (200) 12 (300) 8 (200) The faces of the coupling halves should be
3500 (13247) 12 (300) 12 (300) 8 (200) 12 (300) 10 (250)
4000 (15140) 14 (355) 12 (300) 8 (200) 14 (355) 10 (250) spaced far enough apart so that they cannot
4500 (17032) 16 (400) 14 (355) 8 (200) 14 (355) 10 (250) strike each other when the driver rotor is moved
5000 (18925) 16 (400) 14 (355) 8 (200) 14 (355) 10 (250) hard over toward the pump. Due allowance
should be made for wear of the thrust bearings.
*
Actual pump flange may be less than pump size. The necessary tools for an approximate check
of the alignment of a flexible coupling are a
straight edge and a taper gage or a set of feeler
5.4 Pump Foundation and Alignment. Pumps gases.
should be installed properly. It is very important
that the pump and driver be provided with rigid A check for angular alignment is made by
foundation, and the pump and driver are inserting the taper gage or feelers at four points
aligned. between the coupling faces and comparing the
distance between the faces at four points
5.5 A substantial foundation is important in spaced at 90-degree intervals around the
maintaining alignment. The foundation should coupling. The unit will be in angular alignment
preferably be made of reinforced concrete. when the measurements show that the coupling
faces are the same distance apart at all points.
5.6 If pumps and drivers were shipped from the
factory with both machines mounted on a A check for parallel alignment is made by
common base plate, they were accurately placing a straight edge across both coupling
aligned before shipment. All base plates are rims at the top, bottom, and at both sides. The
flexible to some extent and, therefore, must not unit will be in parallel alignment when the
be relied upon to maintain the factory alignment. straight edge rests evenly on the coupling rim at
Realignment is necessary after the complete all positions. Allowance may be necessary for
unit has been leveled on the foundation and temperature changes and for coupling halves
again after the grout has set and foundation that are not of the same outside diameter. Care
bolts have been tightened. The alignment
should be checked after the unit is piped and
208
CHAPTER 10— PUMPS
must be taken to have the straight edge parallel the piping of the unit has been connected, the
to the axis of the shafts. alignment should be checked again.
Checking Angular Alignment After the units have been in operation for about
10 hours or three months, the coupling halves
When the alignment is correct, the foundation should be given a final check for misalignment
bolts should be tightened evenly but not too caused by pipe or temperature strains. If the
firmly. The unit can then be grouted to the alignment is correct, both pump and driver
foundation. The base plate should be should be dowelled to the base plate. Dowel
completely filled with grout, and it is desirable to location is very important and the
grout the leveling pieces, shims, or wedges in manufacturer’s instructions should be obtained,
place. Foundation bolts should not be fully especially if the unit is subjected to temperature.
tightened until the grout is hardened, usually
about 48 hours after pouring.
209
CHAPTER 10— PUMPS
Right Wrong Open Une nheii pump Enclosed bee shOP pump
Su,face dwcharge Underground discharge
Th,eaded column and bowls Flanged Column and bonds
210
CHAPTER 11 -PIPING
Chapter 11
PIPING
Section 1.0 Scope has a plate so suspended that the reverse flow aids
gravity in forcing the plate against a seat, shutting off
This chapter provides general and specific reverse flow.
requirements not only for plant or building piping but
also for general piping installations. It includes Power Compression Joint A multi-piece joint with cu
—
Piping System Design and pipe color coding for safety shaped threaded nuts which, when tightened
and proper fluid identification in the system. compress tapered sleeves so that they form joint 0:
the periphery of the tubing they connect.
Section 2.0 Definitions
Cross-Over A small fitting with a double offset, ol
—
tight by cement, oakum, lead, or rubber caulked into shaped, allowing fluid to flow when the gate is lifted
the bell around the spigot. from the seat. Such valves have less resistance to
flow than globe valves.
Black Pipe — Steel pipe that has not been galvanized.
Globe Valve One with a somewhat globe shaped
-
or rubber caulked into the bell around the spigot. group of boilers is connected. Also used for a large
pipe from which a number of smaller ones are
Bull Head Tee — A tee the branch of which is larger connected in line and from the side of the large pipe.
than the run.
Malleable Iron Cast iron heat-treated to reduce its
—
211
CHAPTER 11 - PIPING
and wrought iron. Wrought in this sense means 3.16 All steam piping shall be supported on rollers or
worked, as in the process of forming furnace-welded sliding support for expansion.
pipe from skelp, or seamless pipe from plates or
billets. The expression wrought pipe is thus used as a 3.17 All piping carrying pressure shall be of sufficient
distinction from cast pipe. When wrought-iron pipe is bursting strength for the pressure applied. A
referred to, it should be designated by its complete minimum factor of safety of 4 for working
name. pressure applied shall be used.
Section 3.0 General Requirements 3.18 A minimum factor of safety of 4 for working
pressure applied shall be used.
3.1 All piping shall be run parallel to building walls.
3.19 For conveying liquids subject to water hammer,
3.2 Grouped piping shall be supported on racks additional safety factor of a minimum of 100% of
either on horizontal or vertical planes. working pressure shall be used.
212
CHAPTER 11 - PIPING
Electricity
Safety Yellow
1
3.30 Where piping has to be located in trenches the
pipes shall be supported on steel benches on
floor of trench. Light Orange
Communications
3.31 Where piping has to be located in trenches a
suitable drainage or sump for removal of liquid ‘Mite
accumulations shall be provided for trench.
In addition to color coding, the specific contents of
3.32 Where piping carrying steam or hot liquids have piping must be identified by sticker, stencil, tag, etc.
to pass walls of concrete suitable sleeves made
of pipes one size bigger shall be imbedded in 4.2 Color bands and pipe flow identifications shall be
concrete before piping is laid. as specified and installed as shown in page 192.
3.33 Piping to all equipments shall not impose any
stress on equipment being connected.
Section 5.0 Fluid Flow Velocities
3.34 Pipe carrying liquids with solids shall use long 5.1 In practice, the average fluid flow velocities may
radius elbows or tees with plugs in the direction be as follows:
of flow.
a. Water 1.5—3.0 meters/sec.
Section 4.0 Identification Colors for Pipes b. High Pressure Saturated
Steam 25— 50 meters/sec.
4.1 Identification of piping by color, or color bands at
convenient locations shall be as follows:
213
CHAPTER 11 - PIPING
80mm and smaller for pressures above 1724 Carbon Steel casting suitable for ASTM A-216
kPa but not above 2758 kPa. fusion weldingfor high
temoerature service
50mm smaller for pressures above 2578 kPa Alloy-steel casting suitable for ASTM A-217
not above 4137 kPa. fusion welding for high
temperature service
40mm and smaller for pressures above 4137 Forged or rolled steel pipe ASTM A-i 05
kPa may have screwed, flanged, or welding flanges, forged fittings, and
ends. valves and parts for high
temperature service
For all valves, larger than sizes specified in the Forged or rolled steel pipe ASTM A-i81
preceding paragraph, flanged or welding ends flanges for general service
shall be used. Forged or rolled alloy-steel pipe ASTM A-i82
flanges, forged fittings and
Insert Pipe Flow Identification p.192 (PSME) valves and parts for high
temperature service
Factory-made wrought carbon- ASTM A-234
steel and carbon molybdenum-
steel welding fittings
214
CHAPTER 11 - PIPING
215
CHAPTER 11 - PIPING
4 300mm
38mmL
216
CHAPTER 11 - PIPING
Table 11.6.4a equipment on the low pressure side does
not meet the requirements for the full initial
Type of Pipe Value of C in inches pressure. The relief or safety valve shall be
(mm) located adjoining or as close as possible to
Cast-iron Pipe, Centrifugally the reducing valve. Proper protection shall
cast 0.14 (3,556 mm)
be provided to prevent injury or damage
Cast-iron Pipe, Pit-Cast 0.18 (4.527 mm) caused by escaping fluid from relief or
Threaded Steel, Wrought- safety valves if vented to the atmosphere.
iron or Non-Ferrous Pipe The vents shall be of ample size and as
(10mm ) 3/8 in. add smaller 0.05 (1.27 mm) short and direct as possible. The combined
(15 mm) 1/2 in. and larger Depth of Thread in mm discharge capacity of the relief valves shall
Grooved Steel, Wrought-iron be such that the pressure rating of the lower
or Non-ferrous Pipe Depth of Groove in mm pressure piping and equipment will not be
Plain-end Steel or Wrought exceeded if the reducing valves sticks open.
iron
Pipe or tube for 1 in (25 mm) b. It is mandatory that a pressure gage be
Size and smaller 0.05 (1.27 mm) installed on the low pressure side of a
Pipe or tube for sizes above reducing valve.
(25.4 mm) 1 in. 0.065 (1.651 mm)
Plain-end Non-ferrous pipe 6.7 Pipe
or tube 0.000
a. For pressure above 4 137 kPa, the pipe
shall be:
Table 11.6.4 (b)
“Y” Values 1. Seamless steel meeting ASTM
specifica-tions A-106, A-312, A-335
Type of Steel 900°F and 950 1000 1050 1110 1150& above or A-376; or
below
Ferritic
2. Forged and bored steel meeting A-
0.4 0.5 0.7 0.7 0.7 0.7
Austentic 0.4 0.4 0.4 0.4 0.5 0.7
369 or
a. Where pressure reducing valves are used, 5. Electric-Fusion welded steel pipe
one or more relief or safety valves shall be meeting with ASTM specifications
provided on the low pressure side or the A-155.
reducing valve in case the piping or
217
______I_
CHAPTER 11 - PIPING
Table 11.6.5
Allowable Stresses for Pipe in Power Piping Systems
Welded Material:
Furnace Welded
Carbon Steel
A 120 8,800 8,600 8,200 7,800 7,600
Lap Welded
A 120 6,500 6,350 6,100 5,850 5,700
Butt Welded
Automatically Welded
Sustenitic Stainless
Steel
18% chromium,
8% Ni—Ti A312 TP321
75,000 15,950 15,950 14,450 13,450 12,9000 12,650 12,600
18%chromium,
8%Ni.—Cb A312 TP347
Seamless Material
Carbon steel A 120
A 335 10,800 10,600 10,200 9,800 9,600
5%chromium, -
%Mo.
2
/
1 A335 P5
A 369 P5b 60,000 15,000 15,000 15,000 15,000
14,500 14,000 13,700
FP5
18% chromium, - A 312
8% Ni. Ti A 376 TP321
-
Seamless
Red brass B 43 8,000 8,000 7,000 3,000
Copper —
Copper Brazed Steel A 254 Class I 42,000 6,000 5,500 4,750 3,000
Class II 42,000 3,600 3,300 2,850 1,800
Cast iron3
Centrifugally
FSB Types 6,000 6,000 6,000 6,000 6,000
Cast
Metal Molds WWP-421 I & II
ASA A 21.6 6,000 6,000 6,000 6,000 6,000
Sand-lined Molds
Pit cast ASA B 21.8
ASAA21.2 4,000 4,000 4,000 4,000 4,000
1
P ipe in accordance with API Specification.
*For steam at 250 psi (405 F) the values given may be used.
Note: Multiply S in psi by 6.895 to get S in kPa or Divide S in psi by 0.145 to get S in kPa.
*0 = *F —32
1.8
218
CHAPTER 11 - PIPING
Table 11.6.5
Allowable Stresses for Pipe in Power Piping Systems
Note: Where welded construction is used, consideration should be given to the possibility of graphite formation in the
following
steels: Carbon steel above 775 F; Carbon-mdybdenum steel above 875 F; Chrome molybdenum steel (with chromium
under 060)
above 975 F.
ASTM Identi Minimum Values S psi for Temperatures in Dog Not to Exceed
Material Specifi- Grade Ultimate
Fication
cation Symbol Tensile 70 750
11650 800 850 900 950 1,000 1050 1,100 1,150 1,200
Strength
Welded Material:
Furnace Welded
Lap Welded
carbon Steel A 53 45,000 9,000
Wrought Iron A 72 40,000 8,000
Butt Welded
Carbon Steel A 53 45,000 6,70
Wrought Iron 40,000 6,000
Electricfusion welded:
Carbon Steel A 134 A 245 A 48,000 8,800
A 245 B 52,000 9,600
A 245 C 55,000 10,100
A 283 A 45,000 8,300
A 283 B 50,000 9,200
A 283 C 55,000 10,100
A 2830 60,000 10,100
A 139 A4 48,000 9,600 9,250 8,300
B4 60,000 12,000 11,350 9,950
A 155 C45 45,000 10,100 9,800 8,700 7,500 5,950
c50 50,000 11,250 10,900 9,900 8,450 6,550
C55 55,000 12,400 11,900 10,850 9,200 7,000
Killed Carbon Steel KC55 55,000 12,400 11,900 10,850 9,200 7,000
KC6O 60,000 13,500 12,900 11,650 9,700 7,000
KC65 65,000 14,600 13,950 12,450 10,250 7,000
KC7O 70,000 15,750 14,950 13,250 10,800 7,000
Csrbon Molybdemun Steel CM65 65,000 14,600 14,600 14,600 14,100 12,950 11,250
CM7O 70,000 15,750 15,750 15,750 15,200 13,500 11,450
CM75 75,000 16,850 16,850 16,850 16,200 14,300 11,700
1/2% chrom., 1/2% moly steel 1/2CR 65,000 14,600 14,600 14,600 14,100 12,950 11,250 9,000 5.600
1% chrom., 14% moly steel 1CR 60,000 13,500 13,500 13,500 13,250 12,750 11.800 9,000 6.750 4.500 2.500
1 14% chrom., 14% rnoly steel 11/4CR 60,000 13,500 13,500 13,500 13,500 12,950 11,800 9,000 7,000 4,950 3,600
2 14% chrom., 1% moly steel 2 1/4CR 60,000 13,500 13,500 13,500 13,500 12,950 11,800 9,000 7,000 5,200 3,750 2,700
Electric Resistance
Welded:
Carbon Steel A 53 A
3 48,000 10.200 10,200 9.100
3
B 60,000 12,750 12,750 11,000
A 135 A° 48,000 10,200 10,200 9,100
3
B 60,000 12,750 12,750 11,000
Automatically Welded
Stainless Steel:
18% Cr-8% Ni-Ti A 312 TP321 75.000 Note6 12,550 12,550 12,350 12,150 12,000 11,750 11,500 11,150
18% Cr-8% Ni-Cb 750 6,450 4,250
TP347
Seamless Msterial
Carbon Steel A 53 A 48,000 12,000 11,650 10,700 9,000 7,100 5,000
A 53 B 60,000 15,000 14,350 12,950 10,800 7,800 5,000
A 106 A 48,000 12,000 11,650 10700 9,000 7,100 5,000
A106 B 60,000 15,000 14,350 12950 10,800 7,800 5,000
A 83 Type A 47,000
A 179 Low carb. 11,750 11,450 10550 9,000 7,100 5,000
A 192 47,000
A 210 60,000 15,000 14,350 12950 10,800 7,800 5,000
219
Table 11.6.5a
Allowable Stresses for Pipe in Power Piping System (Continued)
formation in the following steels:
Note: Where welded construction is used, consideration should be given to the possibility of graphite
under 0.60) above 975 F.
Carbon steel above 775 F; carbon-molybdenum steel above 875 °F; Chrome-molybdenum steel (with chromium
—32
1.8
CHAPTER 11 - PIPING
NOM. SCHEDULE OUTSIDE INSIDE WALL WEIGHT WTOF OUTSIDE INSIDE TRANS
PIPE NO. + DIAM DIAM THICK- OF PIPE WATER SURFACE SURFACE VERSE
SIZE (in) (in) NESS (Ib/ft) IN PIPE* (sq ft/if) (sq ft/if) AREA
(in) (in) (lb/fl) (sq in)
1/8 40 (S) .405 .269 .068 .244 .0246 .106 .0705 .0568
80(X) .405 .215 .095 .314 .0157 .106 .0563 .0364
1/4 40(S) 540 364 .088 .424 .0451 .141 .0955 .1041
80(X) 540 302 .119 .535 .0310 .141 .0794 .0716
3/8 40(5) .675 .493 .091 .567 .0827 .177 .1295 .1910
80(X) .675 .423 .126 .738 .0609 .177 .1106 .1405
1/2 40(S) .840 .622 .109 .850 .1316 .220 .1637 .3040
80 (X) .840 .546 .147 1.087 .1013 .220 .1433 .2340
3/4 40(5) 1.050 .824 .113 1.130 .2301 .275 .2168 .5330
80(X) 1.050 .742 .154 1.473 .1875 .275 .1948 .4330
1 40(5) 1.315 1.049 .133 1.678 .3740 .344 .2740 .8640
80(X) 1.315 .857 .179 2.171 .3112 .344 .2520 .7190
1 1/4 40 (5) 1.660 1.380 .140 2.272 .6471 .434 .3620 1.495
80 (X) 1.660 1.278 .191 2.996 .5553 .434 .3356 1.283
1 1/2 40(S) 1.900 1.610 .145 2.717 .8820 .497 .4213 2.036
80 (X) 1.900 1.500 .200 3.631 .7648 .497 .3927 1.767
2 40 (5) 2.375 2.067 .154 3.652 1.452 .622 .5401 3.355
80 (X) 2.375 1.939 .218 5.022 1.279 .622 .5074 2.953
2 1/2 40 (S) 2.875 2.469 .203 5.79 2.072 .753 .6462 4.788
80 (X) 2.875 2.323 .276 7.66 1.834 .753 .6095 4.238
3 40 (5) 3.500 3.068 .216 7.57 3.20 .916 .802 7.393
80 (X) 3.500 2.900 .300 10.25 2.86 .916 .761 6.605
3 1/3 40(5) 4.000 3.548 .226 9.11 4.28 1.047 .926 9.89
80 (X) 4.00 3.364 .318 12.51 3.85 1.047 .880 8.89
4 40 (5) 4.500 4.026 .237 10.79 5.51 1.178 1.055 12.73
80 (X) 4.500 3.826 .337 14.98 4.98 1.178 1.002 11.50
5 40 (5) 5.563 5.047 .258 14.62 8.66 1.456 1.321 20.01
80 (X) 5.563 4.813 .375 20.78 7.87 1.456 1.260 18.19
6 40 (S) 6.625 6.065 .280 18.97 12.51 1.735 1.587 28.99
80 (X) 6.625 5.761 .432 28.57 11.29 1.735 1.510 26.07
8 40 (S) 8.625 7.981 .322 28.55 21.6 2.26 2.090 50.0
80 (X) 8.625 7.625 .500 43.39 19.8 2.26 2.006 45.6
10 40 (S) 10.750 10.020 .365 40.46 34.1 2.81 2.62 78.9
60 (X) 10.750 9.750 .500 54.70 32.4 2.81 2.55 74.7
80 10.750 9.564 .593 64.33 31.1 2.81 2.50 71.8
12 30 (S) 12.750 12.090 .330 43.80 49.6 3.34 3.17 115.0
40 12.750 11.938 .406 53.53 48.5 3.34 3.13 111.9
(X) 12.750 11.750 .500 65.40 46.9 3.34 3.08 108.0
80 12.750 11.376 .687 88.51 44.0 3.34 2.98 101.6
14 30 (5) 14.000 13.250 .375 54.60 59.8 3.67 3.46 138.0
40 14.000 13.125 .438 63.37 58.5 3.67 3.44 135.3
(X) 14.000 13.000 .500 72.10 55.8 3.67 3.40 133.0
80 14.000 12.500 .750 106.31 51.2 3.67 3.27 122.7
30 (5) 14.000 15.250 .375 62.40 79.1 4.18 3.99 183.0
16 40 (X) 16.000 15.000 .500 82.77 76.5 4.18 3.93 176.7
80 16.000 14.314 .843 136.46 69.7 4.18 3.75 160.9
(S) 16.000 17.250 .375 70.60 100.8 4.71 3.52 234.0
(X) 16.000 17.000 .500 93.50 98.3 4.71 3.45 227.0
18 40 18.000 16.874 .562 104.75 97.2 4.71 4.42 224.0
80 18.000 16.126 .937 170.75 88.5 4.71 4.22 204.2
20 (S) 20.000 19.250 .375 78.60 126.7 5.24 5.04 291.0
20 (5) 20.000 19.000 .500 104.20 122.5 5.24 4.97 284.0
20 40 20.000 18.814 .593 122.91 120.4 5.24 4.93 278.0
80 20.000 17.938 1.031 208.87 109.4 5.24 4.70 252.7
20 (S) 24.000 23.250 .375 94.60 184.6 6.28 6.08 426.0
(X) 24.000 23.000 .500 125.50 179.0 6.28 6.03 415.0
24 40 24.000 22.626 .687 171.17 174.2 6.28 5.92 402.1
80 24.000 21.584 1218.00 293.36 158.2 6.28 5.65 365.2
*To change Wt of Water in Pipe (lb/fl) to kg/meter of water,
multi. by 1.488
*To change sq ft/ft to sq m/meter, multiply by 0.305
t S is designation of standard wall pipe
X is designation of extra strong wall pipe
221
CHAPTER 11 - PIPING
For pressure above 1724 kPa, but not specifications A-193. For
b.
above 4137 kPa, pipe shall be: temperature exceeding 400°C, only
bolts studes are recommended.
1. Seamless steel in accordance with When cast iron flanges are used,
ASTM specification A-106. bolting material shall be of carbon
steel conforming to ASTM
2. Electric-fusion welded steel pipe of specification A-307, Grade B, or A-
ASTM specification A-i 55. 107, Grade 1120.
222
CHAPTER 11 - PIPING
equivalent to ASTM A-307 Grade B, without a. Piping and equipment shall be supported in
heat-treatment othen than stress relief. a thoroughly substantial and workman like
When bolting such flanges together using manner, rigid enough to prevent excessive
full face gasket, the bolting may be heat vibration and anchored sufficiently to
treated carbon steel (ASTM A-261) or alloy prevent undue strains on boilers and the
steel (ASTM A-193). equipment served. Hangers, supports, and
anchors shall be made of durable materials.
e. 2069 kPa steel flanges may be bolted to In tunnels and buildings of permanent fire
cast-iron valves, fittings, or other parts proof construction, piping may be supported
having either integral Class 1724 kPa cast- on or hung from wood structures if all piping
iron flanges or screwed Class 1724 kPa used for conveying fluid at temperatures
Cast-iron companion flanges without any above 121°C us spaced or insulated from
changes in the raised faces on either flange. such wooden members to prevent
Where such construction is used, the bolting dangerous heating.
shall be of carbon steel equivalent to ASTM
-
A-307 Grade B, without heat treatment other b. Hangers and supports shall permit free
than stress relief. expansion and contraction of the piping
between anchors. All piping shall be carried
6.10 Fittings on adjustable hangers properly leveled
supports, and suitable springs, sway
a. The minimum meal thickness of all flange or bracing, vibration dampeners, etc. shall be
screwed fittings and the strength of factory- provided where necessary.
made welding fittings shall not be less than
that specified for the pressure and 6.13 Pipe Sleeves
temperatures in the respective American
Standards. a. Where steam pipe pass through walls,
partitions, floors, beams, etc., constructed of
b. All fittings in nominal sizes above; 80 mm for combustible material, protecting metal
pressures above 1724 kPa but not above sleeves or thimbles shall be provided to give
2758 kPa; 50 mm for pressures above 2758 a clearance of not less than 6.35 mm under
kPa but not above 4137 kPa, and 40 mm for hot and cold conditions all around the pipe,
pressures above 4137 kPa but not above or pipe and covering. When steam pipes
17238 kPa shall have flanged ends or pass through metal partitions, etc., a
welding ends. clearance of at least 6.35 mm under hot and
cold conditions shall be left all around the
6.11 Gaskets pipe, or pipe covering. In any cases, if the
fluid temperature exceeds 121°C, the pipe
a. Gaskets where required, shall be of material shall be insulated inside the sleeve with a
that resists attack by the fluid carried in the covering of at least standard thickness.
pipe line, shall be strong enough to hold the
pressure, and perform the purpose intended Walls, floors, partitions, beams, etc., shall
throughout the temperature range not be cast solidly to or built up around and
encountered. Gaskets shall be as thin as the in contact with a steam, hot water, or hot oil
finish of the surface that will permit to pipe. Where such pipe must be installed in a
reduce possibility of blowing out. concrete floor or other building member, it
shall be protected for the entire buried
b. Paper, vegetable fiber, rubber or rubber length with a suitable protecting pipes
inserted gaskets shall not be used for sleeve of steel, cast iron, wrought iron, or
temperatures in excess of 121°C. tile; exception maybe taken to the preceding
rules where pipes pass through walls, floors,
c. Asbestos composition gaskets may be used partitions, etc., that must be kept water tight.
as permitted in the American Standard for
steel pipe flanges and flange fittings. This 6.14 Drains, Drips, and Steam Traps
type of gaskets shall not be used on lines
carrying oil or other a. Suitable drains or drips shall be provided
wherever necessary to drain the condensate
6.12 Hangers, Supports, Anchors from all sections of the piping and
223
CHAPTER 11 - PIPING
equipment whenever it may collect. Suitable If a hydrostatic mill test pressure for pipe is
drains shall also be provided to empty water not stated in any of the specifications
lines, water storage tanks, equipment enumerated in Table 11.6.2, the pipe shall
containing water, etc., when such piping and be capable of meeting a minimum internal
equipment is out of service. At least one hydrostatic test pressure determined from
valve shall be placed in each drip or drain the formula.
line.
P 2St
Drip lines from steam headers, mains, D
b.
separators, and other equipment shall be
properly drained by traps installed in Where:
accessible locations and below the level of
the apparatus drained. Drip pumps, drip P = test pressure in kPa
(preferably with orifice control) maybe used
in lieu of traps, if they are safely installed, t nominal pipe wall thickness in
protected and operated under regular mm.
supervision. All drain lines shall have drip
valves for free blow to the atmosphere. D pipe outside diameter in mm,
and
c. Drip lines from steam headers, mains,
separators, and other equipment operating S allowable stress in material in
at different pressures shall not be connected Kilopascal and which shall be
to discharge through the same trap. Where taken as not less than 50
several traps discharge into one header percent of the specified yield
which is or maybe under pressure, a stop pint of the material except that
valve and a check valve shall be placed in hydrostatic tests shall not
the discharge line from each trap. exceed 17 238 kPa for sizes
80 mm and below, or 19 306
d. Trap discharge piping shall have the same kPa for size over 80 mm nor
thickness as the inlet piping unless it is shall the stress produced
vented to atmosphere or operated under low exceed 80 percent of the
pressure and has no stop valves. The trap specified yield point.
discharge piping shall have at least the
pressure rating of the maximum discharge b. After Erection. All piping systems shall be
pressure to which it maybe subjected capable of withstanding a hydrostatic test
against freezing where necessary. Drainage pressure of one and one-half times the
from steam traps, if open to atmosphere, design pressure, except that the test
shall be safeguarded to prevent accidents pressure shall in no case exceed the
from hot discharge. adusted pressure-tern perature rating for
38 C as given in the American Standard for
6.15 Hydrostatic Tests Steel Pipe Flanges and Flange Fittings for
the material and pressure standard involved.
a. Before Erection. All valves, fittings, etc., For systems joined wholly with welded joints
shall be capable of withstanding a the adjusted pressure rating shall be that for
hydrostatic shell test made before erection ring joint facing for systems joined wholly or
equal to twice the primary steam service partly with flanged joints the adjusted
pressure, except that steel fittings and pressure rating shall be that for ring joint
valves shall be capable of withstanding the facing. for systems joined wholly or partly
test pressure as given in the American with flanged joints the adjusted pressure
Standard for Steel Pipe Flanges and rating shall be that for the type of facing
Flanged Fittings for the specific material, used.
pressure standard and facing involved (ring
joint facing for welding ends.) Pipe shall be 6.16 Expansion and Flexibility
capable of meeting the hydrostatic test
requirements contained in the respective a. Piping systems are subject to a diversity of
specifications in Table 11.6.2, under which it loadings creating stresses of different types
is purchased. and patterns, of which only the following
224
CHAPTER 11 - PIPING
more significant ones need generally be joint efficiency maybe disregarded in
considered in piping stress analysis: calculating expansion stresses.
2. Weight of pipe, fittings and valves, a. Piping systems shall be designed to have
containing fluid and insulation, and sufficient flexibility to prevent thermal
other external loadings such as expansion from causing:
wind.
1. Failure from over-stress of the
3. Thermal expansion of the line. piping material or anchors
225
Table 11.6.1 6.2
Thermal Expansion Data
A = Mean Coefficient of Thermal Expansion x lOb (In/In/F] in Going from 70 F to Indicated Temperature
B = Linear Thermal Expansion (In./lOOFt)
. .
.
Temperature Range_— 70 F to
Material Coefficient 200 300 400 500 600 700 800 900 1000 1100 1200 1300 1400
70
Carbon Steel;Carbon-moly steel A 6.38 6.60 6.82 7.02 7.23 7.44 7.65 7.84 7.97 8.12 8.19 8.28 8.36
low-chrome steels (thru 3% Cr) B 0 0.99 1.82 2.70 3.62 4.60 5.63 6.70 7.81 8.89 10.04 11.10 12.22 13.34
A 6.04 6.19 6.34 6.50 6.66 6.80 6.96 7.10 7.22 7.32 7.41 7.49 7.55
Intermediate alloy steels;
B 0 0.94 1.71 2.50 3.35 4.24 5.14 6.10 7.07 8.06 9.05 10.00 11.06 12.05
5 Cr. Mo. thru 9 Cr. Mo.
Austenitic stainless steels A 9.34 9.47 9.59 9.70 9.82 9.92 10.5 10.6 10.2 10.39 10.48 10.54 10.60
B 0 1.46 2.61 3.80 5.01 6.24 7.50 8.80 10.2 11.4 12.84 14.20 15.56 16.92
A 7.76 7.92 8.08 8.22 8.38 8.52 8.68 8.81 8.92 9.00 9.08 9.12 9.18 —I
25 Cr. —20 Ni. m
B 0 7.21 2.18 3.20 4.24 5.33 6.44 7.60 8.78 9.95 11.12 12.31 13.46 14.65
A 7.48 7.68 7.90 8.09 8.30 8.50 8.70 8.90 9.10 9.30 9.50 9.70 9.89 -U
Monel
-
B 0 1.17 2.12 3.13 4.17 5.28 6.43 7.62 8.86 10.1 11.50 13.00 14.32 15.78 z
66 Ni. 29 Cu.
C,
Al u mm urn A 12.95 13.28 13.60 13.90 14.20
B 0 2.00 3.66 5.39 7.17 9.03
Gray Cast iron A 5.75 5.93 6.10 6.28 6.47 6.65 6.83 7.00 7.19
B 0 0.90 1.64 2.42 3.24 4.11 5.03 5.98 6.97 8.02
A 10.03 10.12 10.23 10.32 10.44 10.52 10.6 10.7 10.8 10.90 11.00
Bronze
B 0 1.56 2.79 4.05 5.33 6.64 7.95 9.30 10.8 12.0 13.47 14.92
A 9.76 10.00 10.23 10.47 10.69 10.92 11.6 11.4 11.6 11.85 12.09
Brass
B 0 1.52 2.76 4.05 5.40 6.80 8.26 9.78 11.3 12.9 14.65 16.39
—
E = Modulus of Elasticity Multiply Values by 10°
G = —
Modulus of Torsional Ridigity Mulfiply Values by 106
.
Notes: °C = °F—32
1.82
Table 11.6.16.2b
Moduli of Elasticity and Torsional Rigidity for Non Ferrous Material
—
E Modulus of Elasticity Multiply Values by 106
—
G = Modulus of Torsional Rigidity Multiply Values by 106
.
Temperature, Deg. F
Material Modulus 300 400 500 600 700 800 900 1000 1100 1200
70 100 200
E 26.0 26.0 26.0 25.8 25.6 25.4 24.7 23.1 21.0 18.6 16.0 14.3 13.0
Monel67Ni—300u
66 Ni —29 Cu, Al G 9.5 9.5 9.3 9.1 8.9 8.7 8.5 8.2 7.9
C-)
I
Copper—Nickel E 18.9 18.8 18.4 18.0 17.6 17.2 16.7 16.2 15.3
80—20,70—30 G* -I
m
Aluminum E 10.6 10.6 10.4 10.2 9.5 8.5
F..)
G 3.9 3.9 3.8 3.7 3.5 3.1 -
00
Leaded tin bronze E 13.0 12.9 12.7 12.4 12.0 11.7 11.3 10.9
88 cu, 6 an, 1.5 pb, 4.5 zn G 4.89 4.82 4.65 4.52 4.40 4.72
Notes: °C °F—32
1.82
CHAPTER 11 - PIPING
229
CHAPTER 11 - PIPING
D = nominal outside diameter of pipe, mm Section 7.0 Industrial Gas and Air Piping
Systems
1. The reactions (forces and moments)
Rh and R in the hot and cold 7.1 This industrial air and gas in mines, power
conditions, respectively, shall be plants, industrial and gas manufacturing plants.
obtained as follows from the
reactions R derived from the a. Piping with metal temperature above 232°C
flexibility calculations based on the or below —2.9 °C.
230
CHAPTER 11 - PIPING
Description
. Flexibility Stress Lot. Flexibility
Factor k Factor i
. . .
Characteristic h Sketch
s < r (1 + tan a) 2h
13 . . ,
2
Weldingteel.2
perASAB16.9 2h
13
P4D
Unreinforced 0.9 r
fabricated tee 1 .2 3
h
231
CHAPTER 11 - PIPING
c. Piping lines with firebrick or other refractory Threaded steel, wrought-iron Depth of thread or
material used for conveying hot gases. 0.05 (1.7mm)
whichever is larger
7.2 Wall thickness of Pipe
Grooved steel, wrought-iron Depth of groove
The minimum thickness of pipe wall required
shall be determined by the following formula for Plain end steel or wrought-iron 0.05 (1.7mm)
the designated pressure and for temperature not
exceeding 232 C. D = outside diameter of pipe in inches (mm)
tm = minimum pipe wall thickness in mm, i.e., Alternatively, the effective yield strength maybe
nominal wall thickness less the determined by internal hydrostatic pressure
manufacturing tolerance for the tests on finished lengths of pipe or on cylindrical
thickness. Where available from on samples cut from the results of such tests in
hand or in stock, the actual measured accordance with the following formula:
wall thickness maybe used to calculate
the maximum allowable operating K =Q
pressure. 2t
C = corrosion in millimetre obtained from the Where: K =effective yield strength in kPa
following:
232
CHAPTER 11 - PIPING
Grade A ASTM A-155 14,400 12,500 b. For refrigerants not listed in Table 11.8.2.1
Grade B ASTM A-155 16,200 14,050
Grade C ASTM A-155 18,000 15,600
the design pressure for the high-pressure
Ordinary 14,400 side shall be not less than the saturated
Grade A ASTM A-139 16,800 12,500
Grade B ASTM A-139
vapour pressure of the refrigerant at 54 °C.
3
0.48Y 14,550
ASTM A-134 0.42Y° The design pressure for the low-pressure
side shall be not less than the saturated
Double-submerged arc API 5LX° 0.60Y°
welded vapour pressure of the refrigerant at 32 °C.
For refrigerant not listed in Table 11.8.2.1 &
Electric Resistance-
welded steel: having a critical temperature below 54°C,
Grade A ASTM A-135 18,000 15,600 the design pressure for the high pressure
GradeB ASTMA-135 21,000 18,190
Grade A ASTMA-53
side shall be not less than 1.5 times the
18,000 15,600
GradeB ASTMA-53 21,000 18,190 critical pressure and the design pressure for
GradeA API-5L 18,000 15,600 the low-pressure side shall be not less than
Grade B API-5L 21,000 18,190
API 5LX° 0.51Y° the critical pressure. In no case shall be
design pressure be less than 270 kPa.
Lap-Welded Steel:
233
CHAPTER 11 - PIPING
Table 11.8.2.1
The minimum thickness of pipe wall required
Minimum Design pressure (Psi) for Refrigerant Piping
shall be determined by the following formula:
. High Low
PD Chemical Pressure
tm
.
Material Pressure
Formula Side Side
2S + O.8P
Where: Group I
Carbon dioxide 2
CO 1,500 1,000
tm = minimum pipe wall thickness in mm Dichiorodifluoromethana CCI
F
2 170 85
(Freon- 12)
P maximum internal service pressure in
kPa (plus allowance for temperatures Dichioromethane (Carrene
No.1) Methylene chloride) C1
2
CH 30 30
as provide in Sec. 11.8.2.4 and water
hammer allowance for cast-iron pipe
Dichloromonofluoromethane
as provided in Sec. 11.8.2.3). The (Freon—21) CH CI
F
2 50 30
value of P shall not be taken at less
than 689.5 kPa for any condition of Dichlorotetrafluoromethane
service or material. (Freon—114) C1
2
C
4
F 55 30
4.572mm Butane 10
H
4
C 65 30
Cast-iron pipe, pit-cast 1,000 640
Ethane C
6
H
2
Ethylene 4
H
2
C 1,300 1,050
Threaded steel, wrought-iron Isobutane CH
)
3
(CH 90 40
or non-ferrous pipe Propane 8
H
3
C 300 150
3/8 in, and smaller 1.27mm
1/2 in. and larger Depth of thread
Note: Multiply value by 6.895 to obtain P in kPa.
Grooved steel, wrought-iron
Depth of groove mm 8.4 Piping of Pressure Relieving Devices
or non-ferrous pipe
The most important design factor about
pressure relieving devices is the underlying
234
CHAPTER 11 - PIPING
principle of intrinsic safety. They must “fail safe” a. The inlet and outlet piping can reduce the
or not at all. Therefore, the solution to problems capacity of the device below a safe value.
in pressure relief piping must be based on
sound design practices. Because failure is b. The operation of the device maybe
intolerable, simplicity and directness of design adversely affected to the point where the
should be encouraged as a mass to reliability. opening or closing pressure is altered. In the
case of safety valves*, premature leaking or
There are at least four good reasons why the “simmering” may occur at pressures less
installation of pressure safety valves and disc
than the set pressure or chattering may
should be engineered with care: occur after the valve opens.
Table 11.8.3
Allowable S Values for Pipe and Tubing c. The reaction thrust at the same time the
in Refrigerating Systems device starts to discharge can cause
mechanical failure of the piping.
Material Specification Values of
PSI
d. Good design saves maintenance pesos.
Steel Pipe (Grade A) ASTM A —53 — Pipe
and tubing 8.5
Seamless ASTM A —83— Tube
Safety Valve Inlet Piping
ASTM A —120— Pipe
ASTMA—179—Tube In order to operate satisfactorily, a safety valve
ASTM A —192— Tube
ASTM A —106 Pipe —
must be mounted vertically. It should be directly
API 5L Pipe— 12,000 on the vessel nozzle or on a short connection
Steel Pipe (Grade B) and ASTM A —53— Pipe
Tubing fitting that provides direct and unobstructed flow
Seamless ASTM A 106— Pipe
— between the vessel and the valve. Safety valves
ASTMA—210—Tube 15,000 protecting piping systems should of course be
Steel Pipe, Lap Welded ASTM A —53 Pipe —
235
CHAPTER 11 - PIPING
These recommendations are based on a Up to 1 in. 6 ft. on centers One 1/4 in. 15.0 lbs.
blowdown of a 4 percent. Within this limits, if 1-1/4 in to 2 in. 8 ft. on centers One 3/8 in. 50.0 lbs.
2-1/2 in to 4 in. 10 ft. on centers One 1/2 in. 200.0 lbs.
the blowdown setting is increased, the Two 5/8 in. 400.0 lbs.
5in.to6 in. loft, on centers
pressure drop maybe increased 10 ft. on centers Two 5/8 in. 800.0 lbs.
8 in. to 10 in.
proportionately. Remember however, that 12 in.to 14 in. loft, on centers Two% in. 1,500.0 lbs.
pressure lost in the inlet piping must be 16 in. to 18 in. lOft, on centers Two%in. 2,000.0 lbs
20 in. to 24 in. 10 ft. on centers Two % in. 3,500.0 lbs.
taken into consideration when sizing the
safety valve. Pressure loss in the discharge
piping should be minimized by running the NOTES: A. The maximum weight per span is based
line as directly as possible. Use long-radius on bigger steel pipe size weight full of
bends and avoid close-up fittings. In no case water fittings and insulated.
may the cross-sectioned area of the
discharge pipe be less than that of the valve 1. The copper tubing and fittings (for
instrument air lines) shall be
outlet.
supported not more than 5 feet on
8.7 Piping Supports centers or as shown on the drawings.
Safety valves, although they may not be 2 Vertical risers shall be supported from
included under heading of “delicate the building construction by means of
instruments” , nonetheless instruments. They are approved pipe clamps of U-bolts at
required to measure within three percent and to every floor. Provide slide guides for
perform a specific control function. Excessive pipes subject to thermal expansion.
strain on the valve body adversely affects its Supports shall be of adequate size
ability to measure and control. structural steel shapes or sections
where pipe clamps are too short to
Supports for discharge piping should be connect to the building.
designed to keep the load on the valve to a
minimum. In high temperature service, high B. Pipe Anchors and Restraints:
loads will cause permanent distortion of the
valve because of creep in the metal. Even at low 1. Where piping is subject to thermal
temperature, valve distortion will cause the valve expansion and where expansion
to leak at pressures lower than the set pressure loops, expansion joints and offsets are
and result in faulty operation. The discharge indicated, provide suitably designed
piping should be supported free of the valve and pipe anchors to limit pipe thermal
carefully aligned so that the forces acting on the expansion and over stressing of pipe
valve will be at minimum when the equipment is and adjacent connecting structures.
under normal operating conditions. Expansion
joints or long radius bends of proper design and a. Rigid pipe anchors shall either be
cold spring should be provided to prevent welded type construction or clamp
excessive strain. bolted type whichever is suitable
to the requirement:
The major stresses to which the discharge pipe
is subjected are usually due to thermal b. Directional type pipe anchors
expansion and discharge reaction forces. The where pipe movement is allowed
sudden release of compressible fluid into a in any one plate shall be designed
multi-directional discharge pipe produces an to prevent excessive stresses to
impact load and bourdon effect at each charge the pipe and interference with
of direction. The piping must be adequately adjacent pipes or structure.
anchored to prevent sway or vibration while the
valve is discharging. 2. Piping restraints shall be provided to
prevent unnecessary pipe movements
236
CHAPTER 11 - PIPING
d. The bending moment cause by the reaction Piping in a compressor circuit should connect
thrust of the discharge. directly point to point; bends instead of elbows
give less friction loss and less vibration;
All of these stresses except the latter are angular branch connections eliminate hard
common to practically every problem in tees and give a smoother flow; double offsets
piping stress analysis. for directional change should be avoided;
closely integrated intercoolers with the
The magnitude of the reaction force machine minimizes piping; pulsation
resulting from the instantaneous release of a dampeners should be located on the cylinders
compressible fluid maybe calculated from without any interconnecting pipe; knockout
the two simple formulas given below. drums should be adjacent to the machine;
several aftercoolers or exchangers in the
For safety valve: circuit should be stacked as much as possible
for a direct gas flow; and equipment in the
1
F = (K + 0.2) AP
1 circuit should be in process flow sequence.
237
CHAPTER 12 - METROLOGY
Chapter 12
METRO LOGY
238
CHAPTER 12- METROLOGY
In the older metric system, the simplicity of a applied without introducing such numbers as
series of units linked by powers of 10 is an 550 in power calculations, which, in the
advantage for plain quantities such as English system of measurement have to be
length, but this simplicity is lost as soon as used to convert units. Thus, conversion
more complex units are encountered. For factors largely disappear from calculations
example, in different branches of science carried out in SI units, with a great saving in
and engineering, energy may appear as the time and labor.
erg, the calorie, the kilogram-meter, the liter-
atmosphere, or the horse power-hour. In 1. Mass, weight, force, load. SI is an
contrast, the SI provides only one basic unit absolute system, and consequently
for each physical quantity, and universality is it is necessary to make a clear
thus achieved. distinction between mass and
weight. The mass of a body is
There are six base-units, and in mechanics measure of its inertia, whereas the
calculations three are used, which are for weight of a body is the force exerted
the basic quantities of length, mass, and on it by gravity. In a fixed
time, expressed as the meter (m), the gravitational field, weight is directly
kilogram (kg), and seconds (s). The other proportional to mass, and the
three base-units are the ampere (A) for distinction between the two can be
electric current, the Kelvin (K) for thermo easily overlooked. However, if a
dynamic temperature, and the candela (Cd) body is moved to a different
for luminous intensity. gravitational field, for example, that
of the moon, its weight alters, but its
The SI is a coherent system. A system of mass remain unchanged. Since the
units is said to be coherent if the product or gravitational field on earth varies
quotient of any two unit quantities in the from place to place by only a small
system is the unit of the resultant quantity. amount, and weight is proportional
For example, in a coherent system in which to mass, it is practical to use the
the foot is a unit of length, the square foot is weight of unit mass as a unit of
the unit of area, whereas the acre is not. force, and this procedure is adopted
in both the English and older metric
Other physical quantities are derived from systems of measurement. In
the base-units. For example, the unit of common usage, they are given the
velocity is the meter per second (mis), which same name, and we say that a
is a combination of the base units of length mass of 1 pound has a weight of 1
and time. The unit of acceleration is the pound. In the former case the pound
meter per second squared (mis ).By
2 is being used as a unit of mass, and
applying Newton’s second law motion —
in the latter case, as a unit of force.
force is proportional to mass multiplied by This procedure is convenient in
acceleration — the unit of force is obtained some branches of engineering, but
which is the kg 2 is This unit is known as
m
. leads to confusion in others.
the Newton, or N. Work, or force times
distance, is the kg 2 is which is the joule,
m
, As mentioned earlier, Newton’s
(1 joule = 1 newton-meter) and energy is second law of motion states that
also expressed in these terms. The force is proportional to mass times
abbreviation for joule is J. Power, or work acceleration. Because an
per unit time, is the kg 2 is which is the
m
, unsupported body on the earth’s
watt (1 watt = 1 joule per second = I surface falls with acceleration g (32
newton-meter per second). The abbreviation 2 approximately), the pound
ft/s
for watt is W. (force) is that force which will impart
an acceleration of g Ws2 to a pound
The coherence of SI units has two important (mass). Similarly, the kilogram
advantages. The first is that of uniqueness (force) is that force which will impart
and therefore universality, has been an acceleration of g (9.8 meters per
explained. The second is that it greatly 2 approximately), to a mass
second
simplifies technical calculations. Equations of one kilogram. In the SI, the
representing physical principles can be newton is that force which will
239
CHAPTER 12 - METROLOGY
) to a
impart unit acceleration (lm/s
2 meters is RL Nm, or RL joules.
mass of one kilogram. It is therefore If this work were converted
smaller than the kilogram (force) in entirely into kinetic energy we
the ration 1 :g (about 1:9.8). This fact 2 and it is
could write RL = 1/2 MV
has important consequences in instructive to consider the units.
engineering calculations. The Remembering that the N is the
factory now disappears from a wide same as the kg m/s , we have
2
range of formulas in statics where it (kg )
2
m/s x m = kg 2 which
(m/s)
was formerly absent. It is however is obviously correct. It will noted
not quite the same g, for reasons that g does not appear
which will now be explained. anywhere in these statements.
V
W is the weight in pounds (force),
which leads to familiar expressions appear where formerly it was
absent. Thus, if a rope hangs
V
: V such as WV /2g for kinetic energy.
2
vertically supporting a mass of
V
V In this treatment, the M which
V
V
terms of the slug, a unit normally rope is MgN. Here g is the
V
used only in aeronautical acceleration due to gravity, and
V
engineering. In everyday engineer’s . The ordinary
its units are rn/s
2
language, weight and mass are numerical value of 9.81 will be
V
V
regarded as synonymous and sufficiently accurate for most
expressions such as WV /2g are
2 purposes on earth. The
V
240
CHAPTER 12- METROLOGY
4.2 Instruments for transferring measurements integral with graduated beam on which the
movable jaws slides, with a reference point
a. Calipers and Dividers for inside and outside reading.
b. Telescopic Gages
b. Vernier Calipers a measuring instrument
—
4.3 Angular Measurements which can be used for taking both inside and
241
CHAPTER 12 - METROLOGY
fixtures work necessitate accurately measuring blade shape which are used for checking the
or marking off vertical distances. root diameter of circular form tools as well
as the diameter of circular form tools as well
a. Vernier Depth Gages provide long range
—
as the diameter and depth of narrow slots,
accuracy for determining the depths of keyways, recesses, etc.
holes, slots, and recesses as well as
measuring from a plane surface to d. Quick-adjusting micrometers — allow the
toolmaker’s buttons in locating center spindle to be slid quickly to any point within
distances. their range which makes them particularly
efficient thousandths-reading micrometers
b. Gear Tooth Vernier Calipers used to
—
for checking work where a variety of
check the pitch line thickness of gear teeth dimensions are involved.
by measuring the tooth chord at a specific
distance (chordal addendum) from the top of e. Screw thread micrometers are designed
—
the gear tooth. The Gage consists of two to measure the pitch diameter of screw
independently actuated Vernier calipers, threads to thousandths accuracy by the use
each having its own movable slide, but the of a pointed spindle and double V-anvil
beams and the stationary jaw are made of a which are available for varying diameters of
common single piece. One of the slides has work and each size normally covers a range
the form of a plate, called the tongue of the of the threads-per-centimeter.
instrument, which contacts the top of the
gear tooth, by moving this slide, the Gage f. Inside micrometer — used for measuring
can be adjusted to operate at the desired the diameters of holes and other inside
addendum distance. The second slide, dimensions, consists of a permanent contact
integral with the movable jaw, carries out the micrometer head and a set of
actual chordal thickness measurement at interchangeable rods in various increments
the pitch line. which are seated snugly in the opposite end
of the head against a shoulder and locked
5.4 Micrometer Calipers most useful close
—
securely.
tolerance measuring devices for quick and
accurate measurements to the thousandth part 5.5 Protractor consists of a rectangular head
of a centimeter. graduated in degrees along a semicircle, with a
blade pivoted on the center pin, any angle from
a. Outside Micrometer precision-measuring
—
0 to 180° can be set.
instruments used in determining outside
measurements, and classified into (a) a. Combination protractor and depth gage
Interchangeable anvil micrometers, (b) is a combination of a movable graduated
Multiple anvil micrometers (c) High precision blade (depth gage) and a graduated
micrometers, (d) Dial indicating protractor head.
micrometers, (e) Direct reading
micrometers, (f) V-anvil micrometers, (g) b. Universal bevel protractor consists of a
Disc-type micrometers, (h) Blade type round body with a fixed blade, on which a
micrometers, (i) Quick-adjusting graduated turret rotates. The turret is slotted
micrometers, and (j) Screw thread to accommodate an 18 or 30-centimeter
micrometers. non-graduated blade. Through a locking
mechanism any desired angle and the blade
b. Direct-reading micrometers — are read length can be seen. This tool has a vernier
directly in thousandths from figures reading to 5 minutes and can be furnished
appearing in small windows on the barrel of with or without a fine adjustment feature.
the micrometer, “tenths” (of thousandths) The dial of the protractor is graduated
direct reading micrometers, however, around a complete circle and an angle up to
employ a vernier for establishing the “tenths” 360°can be laid out accurately.
figures.
5.6 Dial Indicator a dial indicator is composed of
—
242
CHAPTER 12- METROLOGY
places not accessible with other indicators dividers, consist of a long bar on which two arms
and also used as an accessory with many or trammels slide. Trammels are designed for
machine tools. layout work and use inside, outside or divider
legs and some are furnished with ball points, to
5.7 Planimeter — the planimeter (planekator) is a permit working from holes. Some are also
tool for checking the flatness of plane surfaces furnished with an adjustable screw on one of the
to tenths-of-thousandths of a centimeter and trams, for fine adjustment of the point for easy
consists of a diabase straight edge, an setting.
adjustable mounting for the straight edge, and a
0.00005 cm. reading indicator. The straight edge 6.4 Gages —a gage is a device used to determine
is always in the same reference plane at every whether the part has been made to the tolerance
position on the surface being checked. Readings required and does not usually indicate a specific
are taken under the straight edge and recorded dimension.
directly into the contour chart of the plane being
checked. Points of equal height are connected a. Telescoping gages cover a range from 4
to form a visual picture of the high and low mm to 150 mm. Two types are commonly
points in the plane. Extreme care shall be taken used in industry. One type has a handle with
in handling this gage to retain its accuracy and one stationary contact and one spring
not to damage the surface being checked. plunger contact with locking device set at
right angles to the handles while the other
Section 6.0 Non-Graduated Manual one has a handle with two plunger-contacts
Measuring Tools at right angles to the handle.
243
CHAPTER 12- METROLOGY
leaves in a case and are designed to check both and oldest method that will
simplest
convex and concave radii. automatically balance the static pressure being
measured against a resisting force whose
7.5 ThicknesslFeeler Gage consists of a number
—
8.4 Fluorescent Penetrants. These are used to b. Limp-Diaphragm Gages — are used for
find surface defects in almost any material. measuring low pressure in boiler houses
and on other implications where low
8.5 Ultrasonic Testing. In ultrasonic testing a high pressures must be accurately measured.
frequency vibration or supra-audible signal is They are also designed for measuring draft
pressure of combustion gases.
244
CHAPTER 12- METROLOGY
c. Bell-type Gages —designed for measuring transmit the live steam pressure to the gage,
low pressure. This type of Gage utilizes the thus preventing gage error and damage
large area of a liquid- sealed bell chamber to caused by the elevated temperature of live
provide the force necessary to actuate an steam. !n applications involving rapid
indicating or recording mechanism and can fluctuations or pulsations in pressure, gage
be made sensitive to the smallest change of snubbers shall be used to throttle the
pressure likely to be significant in an pulsations without seriously obstructing the
industrial application, and yet be rugged passage to the gage. Care shall be taken so
enough to endure considerable that the throttling orifice is not too small
mistreatment. because, if the liquid or gas contains dirt or
foreign materials, the orifice may clog and
d. Piston Gajes suitable for pressure up to
—
block the line to the gage. Pressure gages
350 kg/cm and higher but limited largely to shall not be mounted on equipment
hydraulic applications where oil is the fluid subjected to excessive vibration. External
under pressure. The Bailey power-operated vibrations cause excessive wear and
dead-weight piston Gage is designed for use inaccuracies in gage indications. Wherever
as a master pressure Gage in powerhouse possible, use only gages least effected by
service where a power-operated, sensitive vibration. All pressure gages installed on
Gage with a highly suppressed scale is steam boilers shall have a dial range of less
desirable. than one and one-half (1 %) times and not
more than twice the maximum allowable
9.2 Pressure measurement by deformation of an working pressure and the face of the Gage
elastic membrane is the most universally used shall not be less than 75 mm.
for measuring high and medium-pressure
because of its simplicity, compactness and b. Helical Type of Pressure Gage variations
—
maintenance-free property. It is also widely used of the simple Bourdon type of pressure gage
in the field of low-pressure measurement where wherein the element or tube is wound in the
a large actuating force is not needed. form of a spiral having four or five turns. This
increases the travel of the tip considerably
a. Bourdon tube gage is the most widely used and forms a compact unit easily constructed
industrial pressure Gage applied to both and installed in a pressure gage.
pressure and vacuum, either separately or in
a compound Gage. It is usually used c. Spiral type of element in bourdon type of
whenever the maximum of the required Pressure Gage — the elements is of
range exceeds 1.7 kg/cm 2 for measuring Bourdon type of tube wherein it is wound in
combined pressure and vacuums, for the form of a spiral having several turns
continuous pressure measurements rather than restricting the length of the tube
exceeding 5.6 kg/cm
2 and up to 3500 kg/cm 2 to approximately 270° of arc. This
or more direct pressure measurements, and arrangement in no way alters the theory of
especially where sudden pressure the Bourdon tube but simply has the effect
fluctuations occur which could cause below of producing a tip movement equivalent to
or normal diaphragm to rupture. Bourdon the summation of the individual movements
tubes may be made of any type of materials that would result from each segment of the
that has the proper elastic characteristics spiral considered as a Bourdon tube.
suitable for the pressure range and the Although this construction is more difficult
corrosive resistance of the media to be and expensive to build, it has such an
measured in the application. When bourdon advantage for recording pressure gages that
tube gages are used with corrosive chemical it is almost universally used for all low-and
liquids of liquids that solidity at normal room medium-pressure records. The helical type
temperature diaphragm shall be placed in and the spiral type of elements are widely
the line and the gage line filled with water or used for recording thermometers.
oil and sealed. The sealed system then
senses the diaphragm movement and d. Metallic-diaphragm Pressure Gage —
indicate the pressure. When these gages consists of a metal diaphragm built into
are used to measure steam pressure, a loop diaphragm housing with one side of the
shall be placed in the gage line so that the diaphragm exposed to the pressure to be
liquid condensate is trapped and used to measured and the other under atmospheric
245
CHAPTER 12- METROLOGY
pressure. The pressure transmitted to the scale reading. The standard tilt high
Gage dial by means of a linkage connected precision McLeod gage has been modified
to the center of the diaphragm. to simplify its operations, use less mercury,
be more rugged and compact, and still retain
e. Sector Gear Arrangement - has a large its precision. The newer modified gage is
sector gear mounted at right angles to a link known as the adjustable closed and
connecting the sector gear arm and the improved McLeod gage.
bourdon tube tip movement. A small pinion
gear, to which the pointer is attached, is b. Pirani Gage. The Pirani Gage is a hot wire
then matched to the sector gear. The sector vacuum gage. This gage employs a
gear and the pinion gear are commonly wheatsone bridge circuit to balance the
made of bronze and may be machined, resistance of a tungsten filament or resistor
broached, or stamped, depending on the sealed off in a high vacuum against that or a
quality and accuracy required of the gage. tungsten filament which can lose heat by
conduction to the gas whose pressure is
f. Cam and Roller Arrangement employs a
— being measured. In this circuit the zero drifts
cam sector and a Helicoid roller to which a caused by slight deviations of the bridge
pointer is attached. The Helicoid stainless voltage are compensated for the resistor
steel roller is long wearing and used sealed in the high vacuum. A change in the
especially in services on engines, turbines, filament temperature. This causes a change
blower, hydraulic presses, pumps, and in the filament resistance and unbalances
compressors where violent pressure the bridge. The bridge unbalance is then
pulsations or severe mechanical vibrations read across R 3 as the dry air pressure, by
occur. means of a micrometer, calibrated in
pressure units. The useful range for the
9.3 Electromechanical pressure instruments usually Pirani gage is from 1mm to 100 mmHg. The
employ a mechanical means for detecting the Pirani gage has the advantage of being
pressure, and an electrical means for indicating compact, simple to operate, and can be
or recording the detected pressure. They are opened to the atmosphere without burnout
combinations of mechanical bellows, metallic failure. The main disadvantage is that the
diaphragms, or bourdon tubes with electrical calibration depends on the type of gas in
sensing, indicating, recording, or transmitting which the pressure is being measured.
devices employing pressure transducers, These gages are useful for pressure
inductive transducers, and oscillating measurements involving acetylene, air,
transducers. argon, carbon dioxide, helium,, hydrogen,
and water vapour for the general pressure
9.4 Electronic pressure measuring instruments range of 1 to 200pm (1mm = 1 x 10 meter
normally depend on some physical change that which is equal to 1 x mm) and is most
can be detected and indicated or recorded useful and accurate in the 20 to 200 pm
electronically. range.
9.5 Vacuum Gages-Mechanical, Electrical and c. Knudsen Type Vacuum Gage. The
Electronic. The pressure gages used primarily Knudsen Gage operates on the principle of
for measuring pressure below atmospheric heated gases rebounding from a heated
pressure, which is most often referred to as surface and bombarding a cooled movable
vacuum, are McLeod gages, Pirani gages, surface (vane) spaced less than a mean free
Knudsen gages, thermocouple gages, Phillips path length from the heated surface. The
gages, and ionization gages. The different types, gas particles rebound from the cool vane
except for the Knudsen Gage. with less energy than from the heated vane
which tends to rotate the cool vane away
a. McLeod Gage. The McLeod Gage is a from the heated vane within the restriction of
mercury Gage for the measurement of a suspension system designed to carry a
absolute pressure. It is one of the most galvanometer mirror for producing a reading
basic type and has a measurement range on a fixed scale. The particular advantage of
from 2 pm to mmHg. There are three types the Knudsen Gage operating principle is that
of McLeod gages. The swivel McLeod gage the Gage response is relatively independent
has an accuracy of 3% of reading or mm of of the composition of the gas whose
246
CHAPTER 12- METROLOGY
pressure is being measured. In spite of this relatively good accuracy. The disadvantages
very desirable feature, the Gage is not of these gages is that the filament can burn
widely used because the torsion system is out quickly if it is heated before the pressure
rather delicate and sudden inrushes of air is at low enough vacuum, and to have an
cannot be tolerated. New developments are automatic cut out to protect the ionization
being investigated that may make the Gage tube in case of a system leak or break.
more acceptable for industrial applications
The Alphatron Gage (National Research
d. Phillips Vacuum Gage Phillips gages are
— Corporation) uses a radium source
cold cathode ionization gages which provide sealed in a vacuum chamber where it is
direct measurement for pressure values in equilibrium with its immediate decay
both above and below 1pm. These gages products. This provides a constant
cover the 0.05 to i0 mmHg pressure source of alpha particles for ionizing the
range. The schematic shows the basic Gage gas particles present in the vacuum
circuit. The pressure measurement is a chamber. The alpha particles collide
function of the current produced by a high with the gas molecules in the same
voltage discharge. The electrons drawn from manner as the electrons in the hot
the cold cathode are caused to spiral as filament tube just discussed. The
they move across a magnetic field to the advantages of this Gage are the same
anode. This spiral motion greatly increases as those of the hot Gage, but it
the possibility of collisions with the gas overcomes the burnout problem, the
molecules between the cathode and anode, fragility, and the emission instability.
and produces a higher sensitivity by creating Some of the disadvantages are that at
a higher ionization current. The output is very low pressure a preamplifier is
read out on a micrometer calibrated directly required to give an undistorted output
in pressure units. The range is divided into and the current produced are in order of
four separate outputs with direct reading for 10h1 to 1013 and are directly
each portion of the total range. The proportional to the numbers of ions
advantages of this Gage are the wide range collected on the grid in a given time.
that it can cover, absence of filaments to With proper circuitry the response of the
burn out, rugged metal construction, and gas, within its range, and the indicator or
ease of cleaning and maintenance. The recorder can be made linear with
disadvantages are that cold cathode tubes respect to the pressure, regardless of
are slower to outgas than hot filament tubes, the nature of the gas under
they are adversely affected by mercury, and measurement.
there is a higher breakdown of organic
vapors at higher voltages. These factors All electrical and electronic vacuum
limit the use of these gages, to applications gages now employ the latest solid state
in which oil diffusion pumps are used. circuitry to maintain the constant
àurrents and voltages. This type of
The ionization tube is primary detector and circuitry had added to both the stability
is constructed of glass. It contains an anode, and accuracy of measurements.
a grid, and a filament are attracted to the
grid, pass through the grid, and form ions by e. Vacuum Gage Calibration. The majority of
collision with the molecules present between industrial vacuum application do not require
the grid and the anode. The positive ions are the ultimate in vacuum calibration
collected on the anode, and the electrons techniques. To calibrate the most industrial
are collected on the grid. The positive ion vacuum gages and equipment, a
current created is proportional to the amount comparison gage that covers the calibration
of gas present, if the electron current is kept points from the one im to i0’ mmHg range
constant rate by means of a grid current is sufficient. A precision McLeod gage can
regulator. The advantage of this type of be used as the standard. The calibration
Gage is that very low pressures can be points plotted for the vacuum gage is being
detected and measured in vacuum furnace calibrated as the manifold system is
and mass spectrometer applications. The evacuated. Care must be exercised to
ionization Gage can be used in the 1 micron ensure that a sufficient low pressure is
to 2 x 10:11 mmHg pressure range with reached with hot filament vacuum gages to
247
CHAPTER 12- METROLOGY
prevent filament burn out. Care must also be a. Thermocouple pyrometers in which the
taken to guarantee that filament gages are voltage, generated at the junction of two
properly outgassed during the calibration dissimilar metal wire indicates the degree of
procedure. temperature, the voltage at the junction
increasing proportionally with the
Where calibration are needed for very high temperature.
vacuum technique measuring gages, a
calibrated precision ionization gage should 1. Specifications in the selection of
be used as the standard. This type of Gage thermocouple materials:
has a range down to pressure of 1013 torr.
This type of calibration equipment is (a) Thermocouple wires shall be
expensive and finds applications in the chosen in such a way that they
industrial laboratory rather than in process produce a large electromotive
or manufacturing systems. There are some force that varies linearly with
exceptions such as mass spectrometer temperature,
application for isotopes, and used in special
electron welding chambers. (b) they shall be corrosion — and
oxidation-resistant in the
Section 10.0 Thermometry and Pyrometry atmosphere and temperature
range where they shall be used,
10.1 Indicating and Recording Thermometer —
operators, mechanics, and pipe fitters who commonly used in the 185 to
may have occasion to work near the 300°C temperature range and
installation. superior for measurement of
relatively low temperatures,
d. The angle of the tube at the neck of the bulb especially subzero temperatures
shall be protected. and stand up well against
corrosion and are reproducible
e. The tubing shall never be in contact with hot to a high degree of precision.
steam pipes or stacks which would increase (b) Iron-Constantan — used in
the chance of ambient-temperature errors. reducing atmosphere where
there is a lack of free oxygen
f. The location of bimetallic recording
and useful in the -18 to 760°C
thermometers shall be carefully checked for
the rate of oxidation increases
dirt and dust in the air. rapidly, and so heavier wire
shall be used for 540°C
10.3 Types of Temperature-measuring protection
applications, and
Instruments:
248
CHAPTER 12- METROLOGY
249
CHAPTER 12- METROLOGY
250
CHAPTER 12- METROLOGY
251
CHAPTER 12- METROLOGY
(d) The measurements can be made The phenomenon usually measured is either
with great rapidity, and temperature pressure differential or velocity in the pipe.
gradients easily determine along
any visible part of a heated object. 1. The differential-pressure meters-
252
CHAPTER 12- METROLOGY
to conduct heat will vary with the type, which means that a piston or
velocity, this fact can be used to plungers delivers a fixed volume on
determine the rate and quantity of each stroke used to deliver controlled
flow through the pipe. Two methods volumes at a very high pressure.
are use to determine flow by
conductance —the hot wire a. Nutating-Disc Pump - positive
anemometers which consists of a displacement flowmeter wherin the
small resistance wire inserted in the piston is the only moving part on the
steam of gas whose velocity is to be measuring chamber. The action of
measured, and the Thomas meter the piston resembles the action of
which consists of wire grid inserted the top when it has passed its peak
in the pipe line or duct and supplied speed and starts to wobble or nutate
with a current of sufficient just before it loses speed and goes
magnitude to heat the air passirig out of control. The motion of the
through the pipe. disc piston is controlled by the shaft
Table 12.5
Classification of Temperature Measuring Instrument
—
2. Electromagnetic Flowmeter —
as it moves around the tapered can, this
Electrical primary detectors of the can keeps the lower face of the piston in
rate of flow. In this type of contact with the bottom of the
flowmeter, an electromotive force is measuring chamber on one side of the
induced in the fluid by its motion pump; and keeps the upper face of the
through a magnetic field provided by piston in contact with the top of the
the electiomagnet. The dc measur”i chamber on the opposite.
magnetic field acts vertically through The pist3n is positioned so that the
the pipe that carries the fluid. The lower side of the disc is in contact with
electromagnetic flowmeter is the bottom of the measuring chamber
valuable in measuring the flow of on the left hand side, while the upper
liquid metals, corrosive fluids, side of the disc is in contact with the top
slurries and other conductive fluids of the measuring chamber on the right
and it is not affected by viscosity, and side. This method of pumping
density, or turbulence. produces a smooth and continuous flow
with no pulsation of separate
B. Volumetric and Current types - compartment of the measuring chamber
is successively filled and emptied. The
1. Piston-Type Volumetric Flow Meter — measuring chamber is sealed off into
used to inject an exact amount of fluid separate holds with a definite volume.
into flow line or a collecting vessel. The Nutating piston meters are designed for
piston pump is generally a reciprocating the rate of flow of the liquid to be
253
CHAPTER 12 - METROLOGY
measured and for nominal line The flow of the liquid around the cylinder
pressures. Selection of a meter shall be is restricted by four small semi-circular
based on the flow rate, line pressure, buckets built into flutes in the cylinder
and allowable pressure drop for the surFace and free to rotate about center
intended application. pivots fastened to the meter body, so
that they rotate about their own pivots
b. Rotary Sliding-Vane Flowmeter — simultaneously with the rotation of the
volumetric meter constructed similarly to cylinder upon which they are mounted.
the standard vane type of vacuum The outer edge of the buckets makes a
pump, wherein the design requires that close fit with the meter body and seals
the meter body be in the shape of a the meter at all times from any liquid by
closed drum with shaft carrying a pass. As a result of the rotation of the
smaller cylinder arranged to rotate cylinder and buckets, the liquid trapped
inside the meter body. This shaft is in the buckets or between the buckets
mounted eccentrically with respect to and is therefore metered volumetrically,
the center of the meter chamber, and and the number of revolutions of the
the cylinder is slotted to permit the one rotating cylinder is directly proportional
or more vanes to project from the to the flow.
cylinder to the wall of the meter body.
The rotation of the vanes carries the e. Screw Type of Flowmeter consist of
—
liquid across the meter and forces it out three meshed screws or rotors mounted
on the opposite side because of the vertically and rotating in a measuring
reduction in volume caused by the chamber. The center, or power, screw
eccentric position of the drum with is approximately twice as large in
respect to the meter body. A counter on diameter as the two idler rotors and has
the rotating shaft gives a direct a large thread of special shape
indication of the total flow of liquid designed to seal the meter completely
through the meter. This type of meter by meshing with the idler rotors and
works successfully on the liquid that is provide maximum meter capacity. The
not abrasive or dirty. Dirty liquids are metering chamber is shaped to seal the
very destructive because of the outer edge of the three screws against
comparatively high rotative speeds and any possible by pass of the liquid. The
the large areas subject to wear. screws are located in a straight line, and
hence the chamber cross section is that
c. Oscillating-Piston Flowmeter—consists of a large circle with diametrically
of the hollow piston arranged to oscillate opposite smaller segmented section cut
about the center abutment which is in the large chamber to seal the two
encircled by a confining ring housed in a other idler screws. The head pressure
drum-shaped meter body. Capacity of of the meter forces the liquid in at the
this type of flowmeter ranges fro 8gpm bottom of the screws where it caused
to 7,000gpm, and the error due to the latter to rotate and in so doing is
density or viscosity variation is small. carried up through the measuring
As the rotating parts are close fit, the chamber and out at the top of the meter.
liquid measured must be clean and free The meter counter or register is driven
from abrasive materials. off by the large power rotor through a
gear train which is oil enclosed to
d. Rotating-Bucket Flowmeter — a prevent contact with the liquid in the
positive-dislpacement of a volumetric meter. This type of flowmeter is used in
meter consisting of a meter with a drum liquid with low viscosity; otherwise the
type of body having the outlet and inlets pressure drop across the meter may be
ports side by side with a dividing baffle excessive.
between them. A center cylinder is
suspended concentrically inside the f. Spiral-Vane Flowmeter — consists of
meter body with a close clearance on metering chamber in which a rotor is
the sid3es of the meter chamber and the mounted with a hallow shaft which
diameter approximatelya quarter smaller admits the liquid into a meter. The rotor
than the diameter of the meter body. is similar in design to that of a
254
CHAPTER 12 - METROLOGY
centrifugal air blower with curved blades give a true indication of the volume of
mounted between disc attached to the gas discharged.
rotating shaft. As the liquid flows into
the buckets formed by the spiral blades Roots Type of Volumetric Gas Meter
of the rotor, a rotating action takes place — consist of a set of two rotors having a
something like that which occurs in a cross —sectional area (at right angles to
simple water wheel. If the flow is not the rotating shaft) in the approximately
great enough to fill the meter and in this shape of a figure eight. The rotors are
way flood the spiral vanes, then the so mounted in the right meter body so
rotation of the rotor is a direct indication as to mesh at right angles to each other
of the quantity of fluid flowing, and a by means of two gears mounted outside
counter, or register, on the rotor shaft the meter body on extensions of the
will give the total flow. rotor shafts. The gas is admitted at the
top of the meter, and the head pressure
g. Bellows-Type Gas Flowmeter —
causes the rotors to revolve. In so
designed primarily and exclusively for doing they trap a certain of gas between
gas-receiving bellows having metal the rotors and the meter body. The gas
slides and tanned sheepskin flexible is prevented from by-passing the meter
connections between the metal slides. between the rotors by the close mesh of
These two bellows are mounted the rotors, which almost but not quite
vertically in a tin or steel case and touch at all times. As a result, this
connected through pipes to two slide meter is a true volumetric meter, and the
valves mounted on a vertical plate revolutions of either shaft are a direct
above the bellows and inside the steel indication of the flow.
case. The gas flows from the inlet pipe
alternately into one or the other of the j. Turbine-Type Current Flowmeters —
two bellows. It is in then exhausted into used for measuring flows ranging from
the outer chamber and then passes out 0.003 to 15000 gal/mm as standard
of the meter through an outlet pipe liquid flowmeters, and 20 to 9000 cu.
connected to the gas chamber. A ft/mm as gas flowmeters. Standard and
counter or register of a typical gas-meter pipeline meters flows are dependent on
type is also driven from the crank or the viscosity of the liquid being
gear mechanism. Adjustments are measured, and gas meters on the
usually provided for the stroke of the density of the gas being measured.
bellows and for the timing of the valves Operationally, the turbine rotor is held
to aid in calibrating the meter. between two sets of concentric cylinders
which serve to guide the flow and to
h. Water-Sealed Rotary Gas Meter —
position the rotors in the pipe mounting.
consists of a drum-shaped meter body As the turbine rotors resolves, each
slightly more than half full of water. A vane generates a pulse and represent a
rotor with spirally shaped vanes very unit volume for flow totalization. These
similar to those used in the center of the meters generate a digital electrical
rotor shaft and below the level of the output which is detected by a flowmeter
water which is maintained somewhat or tachometer pick-up coil. The total
above the shaft. It then discharges number of rotor revolution or output
through a short vertical pipe just above pulses is related to the total output or
the water level, after which it is trapped volume of flow. The frequency of the
in the chamber formed by the spiral pulses generated is directly proportional
vane which has both ends submerged to the flow rate of the material being
under the water; the pressure of the gas monitored or measured. The pulses
causes the rotor to revolve. When one generated in the pickup coil are of sine
vane emerges from the water and wave form and can be transmitted
releases the pressure, the next vane electrically over a great distances to a
form a closed chamber and continues to variety of readout devices for
cause the rotor to revolve. If the water computing, indicating, recording,
level is exactly correct, there will be no controlling, and automation.
by-pass, and the rotation of the rotor will
255
CHAPTER 12- METROLOGY
C. Installation of Volumetric Flow Meters. when speed is important. This type of scale is
also a weight balance, but the weights are
All volumetric flowmeters that are subjected to mounted on bent levers, and the movement of
high head pressures should be protected by these pendulum levers are magnified and
means of a by-pass check valve which will transmitted to pointers that swing in a full circle.
relieve the pressure in case the meter should The effective lengths of the two arms of the
become jammed owing to foreign materials. pendulum lever are constantly changing; hence
Otherwise, excessive pressure may be built up to secure uniformly divided scale dials, a cam
and serious damage is done. It is also must be interposed between pendulum and
desirable to install the meter in a by-pass pointer. Some form of damping mechanism
circuit which will permit its removal for such as a fluid dashpot is used with pendulum
servicing without shutting down the process. scales because of their high sensitiveness.
Where a relief valve is installed to by-pass the
meter, it is essential to check it periodically to 12.3 Electrical Scales are combinations of
see that it does not stick, since, if this should mechanical elements and electrical measuring
happen, the meter would develop a serious devices. Weighing can also be accomplished by
error. Where the liquid metered is hot and supporting the load on hydraulic pistons,
likely to solidify in the meter and pipe line if diaphragms, or bellows units and measuring the
allowed to stand, it is necessary to blow the resulting hydraulic pressure with any convenient
meter with steam after each run. In this case pressure gage.
care must be exercised to blow the line clear
by means of a by-pass and then to clear the Section 13.0 The Three Common Methods
meter with only a short period of blowing. If of Rational Speed Measurements
too much pressure is used in blowing out the
meter, it is likely to race in and cause damage a common type of
13.1 Counter and Timer —
256
CHAPTER 12 - METROLOGY
and integrating. The actuating mechanism of looms, and one additional hygrometer
the common tachometer is (1) a centrifugal for every 500 or part of 500 looms, in
device similar in construction to a centrifugal excess of 500.
flyball governor: (2) an electric generator or
magneto: (3) a centrifugal fan, or (4) a vibrating 2. Other departments — One hygrometer
red. for each room of less than 8 500 cubic
meters capacity and one extra
13.3 Stroboscope utilizes the phenomenon of hygrometer for each 5 600 cubic meters
persistence of vision when an object is viewed or part thereof, in excess of this.
intermittently. This is used for speed
measurement with indicating dials calibrated 3. One additional hygrometer shall be
throughout the range 700 to 14 000 rpm and provided and maintained outside each
especially valuable where it is inconvenient to cotton spinning and weaving factory
make a connection or contact with the rotating wherein artificial humidification is
shaft or for light powered machinery where the adopted, and in a position approved by
load to drive speed measuring instruments affect the inspection, for taking hygrometer
the operation of the machine. shade readings.
257
CHAPTER 12- METROLOGY
3. No part of the wet bulb shall be within 3. no water shall be applied directly to the
75 mm from the dry bulb or less than 25 wick or covering during the period of
mm from the surface of the water in the employment.
reservoir shall be below it, on the side of
it away from the dry bulb. e. An inaccurate thermometer must not be
used without fresh certificate. If an Engineer
4. The bulb shall be spherical and of gives notice in writing that a thermometer is
suitable dimensions and shall be freely not accurate, it shall not, after one month
exposed on all sides to the aid of the from the date of such notice, be seemed to
room. be accurate unless and until it has been re
examined as prescribed and fresh certificate
5. The bores of the streams shall be really obtained which certificate shall be kept
distinguishable at a distance of 60 cm. attached to the Humidity Register.
1. the wick and the muslim covering of the 2. Such pipes shall be as short as is
wet tube shall be renewed once a week; reasonably practicable.
2. the reservoir shall be filled with water 3. All hangers supporting such pipes shall
which shall be completely renewed once be separated from the bare pipes by an
a day. The Engineer I Manager may efficient insulator not less than 15 mm in
direct the use of distilled water or pure thickness.
rain water in any particular mill or mills
in certain localities; 4. No uncovered jet from such pipes shall
project more than 100 mm beyond the
outer surface of any cover.
258
CHAPTER 12- METROLOGY
259
CHAPTER 13- MACHINE SHOP MACHINERY AND EQUIPMENT
Chapter 13
Section 1.0 Purpose and Scope 2.3 Shaper — is ordinarily used for finishing flat or
partly curved surfaces of metal pieces few in
To identify each every equipment/machinery and tools number and not over 305 mm or 610 mm long.
in a machine shop and the corresponding operating The cutting tool has a reciprocating (forward and
principles involved. return motion) and cuts on the forward stroke
only. The work is held in a vise bolted to the
Machine shop practice consists of certain mechanical work table and the regular feed is accomplished
principles that are a part of all machine shop work by causing the work table to move automatically
everywhere such as the principles of cutting tools, at right angles to the direction of the cutting tool.
cutting speeds and feeds, actions of gears, screws, The construction of the tool head permits of
cams, etc., applied in the construction of certain down feed at right angles to the regular feed, or
machines and tools and in the various machine at any other angle if desired.
operations: that is, in the methods of holding and
doing work. 2.4 Planer a machine tool used in the production
—
angle results in turning to an angle. The cut at holes where the cutting tool revolves on a
right angles to the axis of the work (cross feed horizontal axis. The spindle which carries the
operation) is called facing or squaring. Cutting cutting tool may be fed longitudinally through the
inside of a hole is boring. spindle head and in the more recent designs the
spindle head may be fed vertically. The work
2.2 Drill or Drill Press — a machine tool used table may be fed longitudinally or transversely.
mainly for producing holes in metal. In this The horizontal boring mill, while designed
machine the work is securely held while a primarily for boring holes, may also be used for
revolving cutting tool is fed into it. The cutting finishing horizontal and vertical flat surfaces by
tool is termed drill. means of a suitable milling cutter fastened to the
spindle.
260
CHAPTER 13— MACHINE SHOP MACHINERY AND EQUIPMENT
261
CHAPTER 13- MACHINE SHOP MACHINERY AND EQUIPMENT
being clamped in a tool holder. The large, solid the tool from digging. Most shaper and planer
tools are specially good for heavy work because manufacturer recommend this type of tool for
they carry away the heat from the cutting edge general work.
of the tool more rapidly, there are also tool
holders using forged bits, the tool holder with the
ground bit is probably the most popular
combination on a shaper.
262
_
CHAPTER 13— MACHINE SHOP MACHINERY AND EQUIPMENT
SIDE blank 4
-1$
ANGLE
\__A
263
_
Gooseneck Finishing Tool for Cast Iron the corners after most of the metal has been
(Fig.3-20.) Made of high-carbon steel. For removed by tool 9. This tool is not so well
finishing flat surfaces in any metal, this tool, suited for general dovetail roughing as is
in combination with a very shallow cut and tool 9, because the sharp corners
of coarse feed, is most satisfactory. breakdown. Made of high-speed steel.
6
a b
a b $
34
,
I. Right-Hand Dovetail End-Cutting
Roughing Tool for Cast Iron (Fig. 3-24.)
similar to tool 9 and intended to clean out
264
CHAPTER 13- MACHINE SHOP MACHINERY AND EQUIPMENT
.
4
L
34
8 C
D
---
---
Squirrel-cage induction motor, when direct
current is not available a gear-box or other
adjustable speed transmission must be
used to obtain different speeds.
265
CHAPTER 13— MACHINE SHOP MACHINERY AND EQUIPMENT
Soft Steel Thickness KW Rating (4) Horizontal Boring, Drilling & Milling Machines
mm mm (Type of Motor: A, B or C)
6.35 6.35 0.37 to 0.75
9.525 9.525 0.37 to 1 Spindle Horsepow Spindle 1KW
12.7 12.7 0.5to2.2 Diam., mm er Diam., mm Rating
15.875 15.875 1 to 1.5 88.9—114.3 11— 18.5 165.1 15—22
19.05 19.05 0.75 to 3.7 127 15-22 177.8—241.3 22—30
22.225 22.225 1 to 3.7
25.4 25.4 1.5 to 4.5
31.75 25.4 2.2 to 6 (e) Hydraulic Wheel Presses
38.1 25.4 5.5 (Type of Motor: B or C)
44.45 25.4 7.5
50.8 25.4 7.5 KW Capacity, 1KW
Capacity,
57.15 28.575 7.5toll Tons Rating Tons Rating
57.15 34.925 11 to 15 2.2—2.6 400 5.5—7.5
100
63.5 38.1 lltol5 3.7—5.5 500 7.5—11
200
76.2 50.8 15 to 18.5 4.5 5.5 9.3 11
300 —
—
266
CHAPTER 13— MACHINE SHOP MACHINERY AND EQUIPMENT
19.05 1.5 to 3.7 63.5 7.5 to 15 and nuts are manufactured have a tensile
25.4 2.2 to 3.7 69.85 11 to 15 strength not less than the following: steel, 40
31.75 3.7 to 5.5 76.2 11 to 18.5 2 (392 N/mm
kgf/mm ); brass, 32 kgf/mm
2 2 (314
38.1 3.7 to 5.5 82.55 15 to 22 ); and aluminium alloy, 32 kgf/mm
2
N/mm ( 314
2
44.45 3.7 to 7.5 88.9 15 to 30 ). The unit, kgf/mm
2
N/mm 2 is in accordance with
50.8 5.5to9 101.6 22to37 ISO DR 911 and the unit in parenthesis has the
57.15 7.5toll ..... relationship, 1 kgf = 9.80665 Newtons. These
minimum strengths are applicable to the finished
(g) Bolt Heading, Upsetting and Forging Machinery products. Steel machine screws conform to the
(Type of Motor: D, E or F) requirements for strength grade designation 4.8.
The strength grade designation system for
Size, mm KW Rating Size, mm KW Rating machine screws consists of two figures, the first
31.75 7.5 76.2 22 is 1/10 of the minimum tensile strength in
38.1 11 101.6 37 kgf/mm2, the second is 1/10 of the ratio
50.8 15 127 45 between the yield stress and the minimum
63.5 18.5 152.4 55 tensile strength expressed as a percentage;
1/10 minimum tensile strength of 40 kgf/mm
2
(h) Bulldozers or Forming or Bending Machines gives the symbol “4”; 1/10 ratio giving the
(Type of Motor: D or E) strength grade
267
CHAPTER 13- MACHINE SHOP MACHINERY AND EQUIPMENT
short for the thread lengths are threaded as fast with cut threads are normally finished with a
as possible up to the head. In these the length chamfer conforming to the dimension. At the
of unthreaded shank under the head does not option of the manufacturer, the ends of screws
exceed 1 % pitches for lengths up to twice the smaller than M6 (6mm diameter) may be
diameter and 2 pitches for longer lengths, and is finished, with a radius approximately equal to 1
defined as the distance from the leading face of
1/
times the nominal diameter of the shank.
a nut which has been screwed as far as possible
onto the screw by hand to: 1) the junction of the
basic major diameter and the countersunk
portion of the head on countersunk and raised
countersunk head; 2) the underside of the head
on other types of heads. Screws of nominal
thread diameter Ml, M 1.2 and M 1.4 and
screws of larger diameters which are too short
for the thread lengths are threaded as far as
possible up to the head. In these the length of
unthreaded shank under the head does not
exceed 1 1/2 pitches for lengths up to twice the
diameter and 2 pitches for longer lengths, and is Section 6.0 Gearing
defined as the distance from the leading face of
a nut which has been screwed as far as possible 6.1 Definition of Gear Terms The terms which
—
onto the screw by hand to: 1) the junction of the follow are commonly applied to various classes
basic major diameter and the countersunk of gearing.
portion of the heed on countersunk and raised
countersunk heads; 2) the underside of the head a. Addendum — Height of tooth above pitch
on other types of heads. circle of the distances between the pitch
circle and the top of the tooth.
5.6 Diameter of Unthreaded Shank on Screws —
The diameter of the unthreaded portion of the b. Arc of Action — Arc of the pitch circle
shank on screw is not greater than the basic through which a tooth travels from the first
major diameter of the screw is not greater than point of contact with the mating tooth to the
the basic major diameter of the screw head and pitch point.
not less than the minimum effective diameter of
the screw thread. The diameter of the c. Arc of Approach Arc of the circle through
—
unthreaded portion of shank is closely which a tooth travels from the point of
associated with the method of manufacturer; it contact with the mating tooth to the pitch
will generally be nearer the major diameter of
the thread for turned screws and nearer the d. Arc of Recess — Arc of the pitch circle
effective diameter for those produced by cold through which a tooth travels from its
heading. contact with the mating tooth at the pitch
point to the point where is contact ceases.
5.7 Radius Under the Head of Screws —The
radius under the head of pan and cheese head e. Axial Plane —In a pair of gears it is the
screws runs smoothly into the face of the head plane that contains the two axes, in a single
and shank without any step of discontinuity. A gear, it may be any plane containing axis
true radius is not essential providing that the and the given point.
curve is smooth and lies wholly within th
maximum radius. Any radius under the head of f. Backlash The amount by which the width
—
countersunk head screws runs smoothly into the of a tooth space exceeds the thickness of
conical bearing surface of the head and the the engaging tooth on the pitch circles. As
shank without any step or discontinuity. actually indicated by measuring devices,
backlash may be determined variously in the
5.8 Ends of Screws When screws are made with
-
transverse, normal or axial planes, and
rolled threads the “lead” formed by the thread either in the direction of the pitch circles or
rolling operation is normally regarded as on the lines of action. Such measurements
providing the necessary chamfer and no other should be converted to corresponding
machining is necessary. The ends of screws
268
CHAPTER 13- MACHINE SHOP MACHINERY AND EQUIPMENT
values on transverse pitch circles for p. Clearance The amount by which the
—
Base Pitch — In an involute gear it is the action to the circular pitch. It is sometimes
pitch on the base circle or along the line of thought of as the average number of teeth in
action. Corresponding sides of involute teeth contact. For involute gears, the contact ratio
are parallel curves, and the base pitch is the is obtain most directly as the ratio is obtain
constant and fundamental distance between most directly as the ratio of the length of
them along a common normal in a plane of action to the base pitch.
rotation. The normal Base Pitch is the base
pitch in the normal plane, and the Axial s. Cycloid The curve formed by the path of a
—
Base Pitch is the base pitch in the axial point on a circle as it rolls along a straight
plane. line. When this circle tools along the outer
side of another circle, the curve is called an
j. Center Distance The distance between
—
Epicycloid; when it rolls along the inner side
the parallel axes of spur gears and parallel of another circle it is called a 1-lypocycloid.
helical gears, or between the crossed axes These curves are used in defining the
or crossed helical gears, or between the American former Standard composite tooth
crossed axes or crossed helical gears and form.
worm gears. Also, it is the distance between
the centers of the pitch circles. t. Dedendum The depth of tooth space
—
the axes at right angles, it contains the of teeth to the number of millimetres of pitch
worm axis. diameter-equals number of gear teeth to
each mm pitch diameter. Normal Diametral
Chordal Addendum The height from the
—
Pitch is the diametral pitch as calculated in
top of the tooth to the chord subtending the the normal plane and is equal to the
circular-thickness arc. diametral pitch divided by the cosine of helix
angle.
m. Chordal Thickness Length of the chord
—
subtended by the circular thickness arc (the v. Effective Face Width That portion of the
—
dimension obtained when a geartooth face width that actually comes into contact
caliper is used to measure the thickness at with mating teeth, as occasionally one
the pitch circle. member of a pair of gears may have a
greater face width than the other.
n. Circular Pitch Length of the arc of the
—
pitch circle between the centers or other b. Efficiency — The actual torque ratio of a
corresponding points of adjacent teeth. gear set divided by its gear ratio.
Normal Circular Pitch is the circular pitch in
the normal plane. x. External Gear A gear with teeth on the
—
between the two sides of a gear tooth, on y. Face of Tooth That surface of the tooth
—
the pitch circles unless otherwise specified. which is between the pitch circle in the top
Normal Circular Thickness is the circular of the tooth.
thickness in the normal plane.
269
CHAPTER 13— MACHINE SHOP MACHINERY AND EQUIPMENT
a central clearance groove, the width of this involute gears. It is the straight line passing
groove is not included in the effective face through the pitch point and tangent to the
width. base circles.
tooth profile where it joins the bottom of the The smallest diameter on a spur gear at
tooth space. The approximate radius of this which a single tooth of one gear is in contact
curve is called the Fillet Radius. with its mating gear, often referred to as
LPSTC. Gear set contact stress is
bb. Flank of Tooth That surface which is
—
determined with a load placed at this point
between the pitch circle and the bottom on the pinion.
land. The flank includes the fillet.
nn. Module Ratio of the pitch diameter to the
—
ee. Highest point of Single Tooth Contact — surfaces at a point of contact, and
The largest diameter on a spur gear at perpendicular to the pitch plane.
which a single tooth is in c’ntact with the
mating gear. Often referred to as HPSTC. pp. Pitch —The distance between similar,
Gear tooth fillet stress is determined with the equally-spaced tooth surfaces in a given
operating load placed at this diameter. direction and along a given curve or line.
The single word “pitch” without qualification
if. Internal Diameter The diameter of a circle
—
has been used to designate circular pitch,
coinciding with the tops of the teeth of an axial pitch, and diametral pitch, but such
internal gear. confusing usage should be avoided.
inner cylindrical surface. equal to the distance from the gear axis to
the pitch point.
hh. Involute The curve formed by the path of
—
a point on a straight line, called the rr. Pitch Diameter The diameter of the pitch
—
generatrix, as it rolls along a convex base circle. In parallel shaft gears the pitch
curve. (The base curve is usually a circle.) diameter can be determined directly from
This curve is generally used as the profile of the distance and the numbers of teeth by
gear teeth. proportionality. Operating Pitch Diameter is
the pitch diameter at which the gears
ii. Land The top Land is the top surface of a
—
operate. Generating Pitch Diameter is the
tooth, and the Bottom Land is the surface of pitch diameter at which the outer ends of the
the gear between the fillets of adjacent teeth unless otherwise specified.
teeth.
ss. Pitch Plane — In a pair of gears it is the
jj. Lead — The distance a helical gear or plane perpendicular to the axial plane and
woman would thread along its axis one tangent to the pitch surface. In a single gear
revolution of it were free to move axially. it may be any plane tangent to its pitch
surface.
kk. Length of Action The distance on an
—
involute line of action through which the tt. Pitch Point This is the point of tangency
—
270
CHAPTER 13- MACHINE SHOP MACHINERY AND EQUIPMENT
pitch line) and is on the line of center. The ccc. Tangent Plane A plane tangent to the
—
pitch point of a tooth profile is at its tooth surfaces at a point or line of contact of
intersection with the pitch circle. material is removed near the tip of the gear
tooth.
uu. Plane Rotation — Any plane perpendicular
to a gear axis. ddd. Tip Relief An arbitrary modification of a
—
line of action and the line tangent to the dimension of a gear blank. It may exceed
pitch circle. Standard Pressure Angles are the effective face width, as in the case of
established in connection with standard double-helical gears where the total face
gear-tooth proportions. A given pair of width includes any distance separating the
involute profiles will transmit smooth motion right-hand and left-hand helical teeth.
at the same velocity ratio even when the
center distance is changed. iff. Transverse Plane A plane perpendicular
—
involute. The radian measure of this angle is space, equal to addendum plus dedendum,
the tangent of the pressure angle of the also equal to working depth plus clearance.
point on the involute.
kkk. Working Depth The depth of engagement
—
aaa. Root Circle — A circle coinciding with or of two gears, that is, the sum of their
tangent to the bottoms of the tooth spaces. addendum’s. The standard working distance
is the depth to which a tooth extends into
bbb. Root Diameter — Diameter of the root circle. the tooth space of a mating gear when the
center distance is standard.
271
CHAPTER 13— MACHINE SHOP MACHINERY AND EQUIPMENT
hk = Working Depth of Tooth given for finding the outside and root diameters
h = Whole Depth of Tooth of spur gears with various types of standard
N = Number of Teeth teeth using the data for pitch diameters,
If both gear and pinion are referred to: addenda, and the dedenda. It will be noted from
NG = Number of Teeth in Gear the formula given that the root diameter for a
N = Number of Teeth in Pinion gear of given pressure angle and type of tooth
p = Circular Pitch depends upon whether the gear is being
P = Diatmetral Pitch hobbed, shaped, or pre-shaved. When gears
are finish-hobbed the standard preferred
No. To Find Formula dedendum is used. When gears are cut on the
General Formulas generating type of gear shaper the clearance is
1 Base Circle Diameter Db = D cos 0 made larger so that a dedendum greater than
standard is required. In preparing gears for
2a Circular Pitch p = 3.1416D shaving, it is necessary to semi-finish hob or
N shape the gears deeper than standard depth in
order to avoid interference between the tips of
2b Circular Pitch p = 3.1416 the shaving cutter teeth and the fillet at the base
P of the gear tooth.
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CHAPTER 13- MACHINE SHOP MACHINERY AND EQUIPMENT
shaper or hobbing machine, a gear tooth caliper b. The root radius may vary within the limits
or pins would be employed. 0.25 to 0.39.
When the pre-shaved gear can be removed c. Tip relief may be applied within the limits
from the machine for checking, the center shown.
distance method may be employed. In this
method, the pre-shaved gear is mashed without
backlash with a gear of standard tooth thickness
and the increase in center distance over 0.02
max
06
standard is noted. The amount of total tooth max
thickness over standard is left on the pre-shaved
gear can then be determine by the formula: t
2 tan 0 x d, where: t 2 = amount that total
2 = EZ\J
thickness of the tooth.
gears in the inch system. module of a gear equals the pitch diameter
divided by the number of teeth, whereas
6.5 Notation To promote the international usage
— diametral pitch equals the number of teeth
of common gear terminology, the terms of draft divided by the pitch diameter. The module
ISO Recommendation No. 888, International system is in general use in countries which have
vocabulary of gears’ have been adopted, and adopted the metric system; hence the term
the notation is derived from ISO module is usually understood to mean the pitch
Recommendation R701 ‘International gear diameter in millimetres divided by the number of
notation, symbols for geometrical data. teeth. The module system
Recommendation R53 ‘Basic rack of cylindrical Normal Metric Modules (B.S. 436: Part 2: 1970)
gears for general and heavy engineering.’ In
practice, the basic rack tooth is usually modified, Preferred 1 1.25 1.5 2 2.5 3 4 5 6
and the extent of modification shall be in Modules
accordance with the following: Second 1.13 1.38 1.75 2.25 2.75 3.5 4.5 5.5 7
Choice
a. The total depth may vary within the limits Modules
2.25 to 2.40 which permits an increasing
Preferred 8 10 12 16 20 25 32 40 50
root clearance within the same limits to Modules
allow for the use of different manufacturing Second 9 11 14 18 22 28 25 45
processes. Choice
Modules
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CHAPTER 13— MACHINE SHOP MACHINERY AND EQUIPMENT
The values are in millimetres. 6 2.5/1 + 6.3 0.63 øf + 6.3 1 .0/b + 5.0
*Wherever possible, the preferred modules should be 7 3.55/1 + 9.0 1.0 øf + 8.0 1 .25/b + 6.3
applied rather than those of second choice. 8 5.1/1 + 12.5 1.6 øf+ 10.0 2.0/b + 10.0
9 7.1/1 + 18.0 2.5 øf+ 16.0 3.15/b +16.0
10 10.0/1 + 25.0 4.Oøf+25.0 5.0/b+ 25.0
11 14.0/1+35.0 6.3øf+40.9 8.0/b+40.0
12 20.0/1 + 50.0 10.0 øf + 63.0 12.5/b + 63.0
Limits of
Limits of Limits of
Gear Tolerance on
Tolerance Tolerance
Accur Tooth-to-
on Radial on Total
acy Tooth
Run out of Composite
Grade Composite
Teeth Error
Error
Te flanks or sides are straight (invoiste system) and the pressure angte is 20 degrees.
The shape of the root stearance space and the amount of clearance defend upon the method 3 0.56 øp + 7.1 0.32 p + 4.0 0.8 øp + 10
of cutting and special requirements. The amount of clearance may vary from 0.1 x rnoduln to
0.3 x module. 4 0.90 øp+ 11.2 0.45øp+5.6 1.25 øp+ 16.0
5 1.40 p + 18.0 0.63 p + 8.0 2.0 øp + 25.0
To Find Module Known Circular Pitch known
6 2.24 øp + 28.0 0.9 øp ÷ 11.2 3.l5øp + 40.0
Addendum Equals module 0.3 183 x circular pitch* 7 3.15 øp ÷ 40.0 1.25 øp +16.0 4.5 øp + 56.0
Dedendum 1.157 x module* 0.3183 x Circular pitch* 8 4.0 øp + 50.0 1.8 øp + 22.4 5.6 øp + 71.0
1.167 x module* 0.3ll4xCircularpitch** 5.0 øp + 63.0 2.24 øp+28.0 7.1 øp + 90.0
9
Working Depth 2 x module 0.6366 x Circular pitch** 10 6.3 øp + 80.0 2.8 p + 35.5 9.0 øp ÷ 112.0
1.157 x module* 0.6866 x Circular pitch** 11 8.Oøp+ 100.0 3.55øp45.0 ll.2øp+l4O.0
Total Depth
1.167 x module** 0.6896 x Circular pitch 12 10.0 øp+125.0 4.5 øp + 56.0 l4.Oøp+18O.0
Total Thickness on
1.5708 x module 0.5 x Circular pitch**
Pitch Line
Fig.13.6.7 German Standard Tooth Form form Spur The Limits of Tolerance are in micro-meters.
and Bevel Gears.
The values of symbols given in the above formulas
are:
number of teeth. The module system may,
however, also be based upon inch
I = any selected length of arc in millimetres, are less
measurements and then it is known as English
than d/2.
module to avoid confusion with the metric
module. Module is an actual dimension,
of = ma + 0.1 d, where ma = normal module, and
whereas diametral pitch is only a ratio. Thus, if
d = reference circle diameter in mm.
the pitch diameter of a gear is 50 millimeters
and the number of teeth 25, the module is 2
b = face width in mm, up to a maximum of 150 mm.
which means that there are 2 millimeters of
pitch diameter of each tooth. Table 13.6
op = ma + 0.25 d, where ma = normal module, and
“Tooth Dimensions Based Upon Module
d = reference circle dia.
System” shows the relation between module,
diametral pitch, and circular pitch. (*) are
Formulas for dedendum and total depth marked
used when clearance equals 0.157 x module.
Table 13.4
Formulas marked (**) are used when clearance equals
British Standard Metric Spur and Helical Gears —
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CHAPTER 13- MACHINE SHOP MACHINERY AND EQUIPMENT
Table 13.5
Rules for Module System of Gearing Diametral Rule: To find the diametral pitch
Pitch equivalent to a given module, divide 25.4
Equivalent to by the module (25.4 = number of
Rule 1: To find the metric module, divide Metric millimeters per inch.)
the pitch diameter in millimetres by the Module
number of teeth. Example: The module is 12; determine
equivalent diametral pitch
Example 1: The pitch diameter of a gear
is 200 millimeters and the number of equivalent diametral pitch = 25A = 2:17
teeth, 40; then 12
module 200 = 5
= Note: A diametral pitch of 2 is nearest
40 standard of equivalent.
Metric Rule 2: Multiply circular pitch in
Module millimetres by 0.3183 Rule: Multiply number of teeth by module
Rule: To find the metric module turrets lathes, hollow spindle lathes, automatic
equivalent to a given diametral pitch, lathes and automatic screw machines.
divide 25.4 by the diametral pitch.
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CHAPTER 13— MACHINE SHOP MACHINERY AND EQUIPMENT
Table 13.6
(c) Flying of metal (1) Enclosure guard Tooth Dimensions Based Upon Module System
chips or long (2) Portable perspex
burrs and screenguard Addendu Whole Whole
Me
DIN
Equivalent J Millimet
Circular Pitch
m, Dedendum, Depth Depth, 1’
turnings (3) Use chip breaker-tool to Standar
Diametral
Inches Millimeter Millimeters* Millimeter Millimeter
Pitch ers a s S
eliminate long turnings dSeries
6.35 0.650 0.647
0.3 84.667 0.943 0.0371 0.3
0.4 63.500 1.257 0.0495 0.4 0.467 0.867 0.863
0.5 50.800 1.57 1 0.0618 0.5 0.583 1.083 1.079
0.6 42.333 1.885 0.0742 0.6 0.700 1.300 1.294
(d) Hand braking (1) Foot-pedal brake with 0.7 36.286 2.199 0.0865 0.7 0.817 1.5 17 1.510
of machines triple-switch 0.8 31 .750 2.513 0.0989 0.8 0.933 1.733 1.726
0.9 28.222 2.827 0.1113 0.9 1.050 1.950 1.94 1
(2) Pneumatic chuck and 25.400 3.142 0.1237 1.167 2.167 2.157
freeding tools for small 1.25 20.320 3.927 0.1546 1.25 1.458 2.708 2.697
1.5 16.933 4.712 0.1855 1.5 1.750 3.250 3.236
jobs 2.042 3.792 3.774
1.75 14.514 5.498 0.2164 1.75
2 12.700 6.283 0.2474 2 2.333 4.333 4.314
(1) Automatic emerging 7.069 0.2783 2.25 2.625 4.875 4.853
(e) Filling 2.25 11.289
2.50 2.917 5.417 5.392
2.5 10.160 7.854 0.3092
emerging Emery holder 2.75 9.236 8.639 0.3401 2.75 3.208 5.958 5.932
without a 3 8.466 9.425 0. 37 11 3.00 3.500 6.500 6.471
3.25 7.815 10.2 10 0.4020 3.25 3.791 7.041 7.010
suitable device 3.5 7.257 10.996 0.4329 3.50 4.083 7.583 7.550
3.75 6.773 11.781 0.4638 3.75 4.375 8.125 8.089
12.566 0.4947 4.0 4.666 8.666 8.628
(f) Gauging the (1) Dial indicators. 4 6.350
4.5 5.25 9.750 9.707
4.5 5.644 14. 137 0.5566
job while 5 5.080 15.708 0.6184 5.0 5.833 10.8331 10.785
17.279 0.6803 5.5 6.416 1.9 1613 11.864
machine is in 5.5 4.618
7.000 .000 12.942
6 4.233 18.850 0.7421 6
motion. 6.5 3.908 20.420 0.8035 6.5 7.583 14.083 14.021
7 3.628 21.991 0.8658 7 8.166 15.166 15.099
8 3.175 25.132 0.9895 8 9.333 17.333 17.256
(g) Attempting to (1) Safety hook/brush. 2.822 28.274 0.1132 9 10.499 19.499 19.413
9
clean chips 10 2.540 31 .416 1.2368 10 11.666 21 .666 21 .571
11 2.309 34.558 1.3606 11 12.833 23.8332 23.728
when job is in 2.117 37.699 1.4843 12 14.000 6.00028 25.684
12
motion. 13 1.954 40.841 1.6079 13 15. 166 .166 28.04 1
14 1.8 14 43,982 1.7317 14 16.332 30.332 30. 198
15 1.693 47. 124 1.854 1 15 17.499 32.499 32.355
(h) Projection of (1) Tube guard 16 1.587 50.266 1.9790 16 18. 666 34.666 34. 512
the work or (2) Bar-stock guard 18 1.411 56.549 2.2263 18 21.000 39.000 38.826
20 1.270 62.832 2.4737 20 23.332 43.332 43. 142
stock 22 1.155 69.115 2.7210 22 25.665 47.665 47.454
beyond 24 1.058 75.398 2.9685 24 28.000 52.000 51 .768
27 0.941 84.823 3.339 27 31 .498 58.498 58.239
machine 94.24 3.7 11 30 35.000 65.000 64.713
30 0.847
33 0.770 103.673 4.082 33 38.498 71 .498 71.181
(1) Splash guard 113.097 4.453 36 41.998 77.998 77.652
(i) Flying off the 36 0.706
45.497 84.497 84. 123
39 0.651 122.522 4.824 39
job from the (2) Full enclosure guard 42 0.605 131 .947 5.195 42 48.997 90.997 90.594
two centres 45 0.564 141.372 5.566 45 52.497 97.497 97.065
50 0.508 157.080 6.184 50 58.330 108.330 107.855
due to sudden 55 0.462 172.788 6.803 55 64.163 119.163 118.635
movement of 60 0.423 188.496 7.421 60 69.996 129.996 129.426
65 0.391 204.204 8.040 65 75.829 140.829 140.205
the tool jerking 219.911 8.658 70 81 .662 151 .662 150.775
70 0.363
back of the tail 75 0.339 235.619 9.276 75 87.495 162.495 161 .775
stock
(j) Inserting Spindle jaws, Mechanical *Dedendum and total depth when clearance = 0.1666
blanks and feeding device like that of x module, or one-sixth module.
moving the F.H.J. Safety fixture tTotal depth equivalent to American standard full-
processed pert- depth teeth. (Clearance = 0.157 x module.)
without
stopping
Special Accidents in Turrets & Capstan Lathes:
(k) Splashing of Splash guard/Enclosure (a) Counter-wL falling (1) Tube guard
coolant guard mounted on rollers. and bar flying thro’ (2) Blank off hole
resulting in turret head
slipping Special Accident in Multispindle Lathe:
hazards and (a) Collecting component Wire-mesh, spoon
dermatitis while just parting off
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CHAPTER 13— MACHINE SHOP MACHINERY AND EQUIPMENT
(b) Top parted off Sharpening tools properly (a) Removing swan by Brush, Magnetic
component comes in hand using rag to sweep
between tool and of clean excess oil while
first spindle. it is running
(a) Contact with the spindle relescopic chuck (e) Slipping of spanner Use of proper spanner
and drill bits and spindle guard while adjusting,
tighten, loosening etc.
(b) Breaking ofa tool and Clamps or use of
lunt it bit L angle iron (f) Attempting to remove Education and
the nut from the Training
(c) Being struck by a job Clamps or use of machine arber by
due to insecurely L angle iron applying power to the
clamped work machine
clothing. Fixed guard, automatic guard and planning operation include basic planer, shaper,
interlocked guard of innumerable kinds are slotters, broacher and key seaters. Modern
available for thee, as described. machine tools are designed and built in such a
way that all the transmission parts are guarded
Horizontal & Vertical Bed Movement. properly with built-in guards. Point of operation
guarding is to made according to operation.
About 2/3 of all milling machine accidents occur
when operators unload and load, or make a. Hazards in Planers Struck by the moving
—
adjustments, when running. Other causes of table or by material on the table; caught
injuries are: between the table and the frame or bed of
the machine. In case of huge planning
machines a fall from the table or the bed, fall
277
CHAPTER 13- MACHINE SHOP MACHINERY AND EQUIPMENT
between the uprights may be a serious a. Accidents occur due to the following:
matter. Unsafe practices such as changing
stop dogs when the machine is in motion, 1. Failure to use suitable protective
riding the table during the operation. equipment like goggle face shield
Hazards lie in handling material into or out etc.
of machine and removing chips. 2. Holding the work improperly.
3. No work rest or improperly adjusted
Guard rail or barrier to close off any space work nest.
less than 457.2 mm between fixed part and 4. Improper or no wheel guard.
planner bed. Self adjusting table guard on 5. Excessive wheel speed.
the sides of the planner are essential. 6. Cleaning, adjusting or gauging work
while the machine is in motion.
b. Hazards in Shapers — Flying chips; flying 7. Side grinding
job if the work is not securely clamped; 8. Using wrong type of wheel.
attempting to adjust machine while it is in 9. Bursting of wheels, due to
motion; caught between ram and fixed excessive tightening or damage in
object and out injuries in removing chip. transit.
Shaper can be provided with a combination 10. Applying work too quickly to a cold
container for chips and transparent shield wheel.
for tool, a retriever to the limit of the stroke 11. Vibration due to improper balance.
of ran channel. The reversing dogs on the 12. Applying too heavy a cut.
planers and shapers should be covered. If 13. Using a spindle with incorrect
the planner bed travels within 457.2 mm of a diameter.
wall or fixed objects, there should be barrier 14. Threads on spindle tends to loosen
to prevent entrapping. the nut as spindle revolves.
15. Wrong size of flanges or flanges of
Breaches may be covered with transparent unequal diameter.
cover and guarded by two-hand electric 16. Flanges with un-relieved centers.
interlocks. 17. Failure to use wheel washers.
18. Wheel out of balance.
7.5 Grinding Machines Internal grinding, external
—
19. Grinding too high above the centre
or cylindrical grinding, surface grinding, line of the wheel.
polishing, buffing, honing are classified under 20. Incorrect dressing of the wheel.
this cadre.
7.6 Proper Inspection and Storage:
Wheel guard and eye shield can be fitted to
prevent the most common accident due to flying (a) “Ring” test by qualified person.
of particles on tool grinders. Segment guard for (b) Proper storing in dry area.
portable grinders. Wheel guard and enclosure (c) Then speed test while installing.
for surface grinders:
278
CHAPTER 14- MANUFACTURING PROCESS
Chapter 14
MANUFACTURING
PROCESS
and die casting industries. 2.1 Processes used to change the shape of materials
products from metallic powders by pressure. In this group of processes, material is changed
into its primary form for some selected part.
Spinning — The operation of shaping thin metal by Sometimes, the parts are suitably finished for
pressing it against a form while it is rotating. commercial use, as in metal spinning, cold rolling
of shafting, die casting, stretch forming of sheet
Swaging A force in impact which causes the metal to
—
metal and drawing wire. Other times neither the
flow in some predetermined shape according to the dimensions nor the surface finish are satisfactory
design of the dies. for the final product, and further work on the part
is necessary. It should be noted that the last
Toughening A form of tempering used to enhance
—
three processes, eleCtroforming, the forming of
the toughness of a hardened steel where high hardness powder metal parts and plastic moulding do not
is not particularly needed in service. originate as a casting. Electroformed parts are
produced by electrolytic deposition of metal onto
Ultra Sonic Impact Grinding A means of cutting
—
a conductive performed pattern. Metal is supplied
shapes of all kinds by the rapid motion of abrasive from the electrolyte and a bar of pure metal that
particles. acts as an anode. Parts of controlled thickness,
having high pressure can be made by this
process. The method used in the production of
279
CHAPTER 14— MANUFACTURING PROCESS
powder metal products requires a heating Chemical machining is done either attacking the
operation to assist in bonding the particles metal chemically or by using a reverse plating
together. Plastic are molded under heat and/or process.
pressure to conform to the configuration of a
mold. Explosive, electrohydraulic, and magnetic 2.3 Process for obtaining a surface finish. Surface
forming are high-energy rate processes in which finishing operations are used to insure a smooth
parts are formed very rapidly by extremely high surface, great accuracy, aesthetic appearance, or
pressures. protective coating. Processes used are:
2.2 Processes used for machining parts to a fixed Polishing Abrasive belt grinding Barrel tumbling
Electroplating Honing Lapping
dimension Super finishing Metal Spraying Inorganic coating
Parke rizing Anodizing Sheradizing
Traditional machining, chip removal
Non-traditional machining In this group there are processes that cause little
change in dimension and result primarily in
a. In manufacturing any product there are finishing the surface. Other processes, such as
usually a number of machining operations, grinding, remove some metal and bring the part
which may be classified as follows: to a pre-planned dimension in addition to giving it
a good finish. In the processes such as honing,
Turning Planning Shaping Drilling lapping and polishing it is a matter of removing
Boring Reaming Sewing Broaching
Milling Grinding Robbing Routing small scratches with little change in dimension.
Super finishing is also a surface improving
b. Non-traditional machining process: process that removes undesirable fragmented
metal, leaving a base of solid crystalline metal.
ultrasonic Electrical discharge Electro-Arc Plating and similar processes, used to obtain
Optical laser Electrochemical Chem-Milling corrosion-resisting surfaces or just to give a
Abrasive jet cutting Electro beam machining Plasma-Arc better appearance, do not change dimensions
machining
materially.
In these secondary operations, which are
2.4 Process used for joining parts of materials.
necessary for many products requiring close
Products requiring the assembly of two or more
dimensional accuracy, metal is removed from the
parts are usually joined by one of the following
parts in small chips. Such operations are
processes:
performed on machine tools which include the
various power-driven machines used for culling Welding Soldering Brazing Sintering
metal. All of these operate on either a Pressing Riveting Screw Fastening Adhesive joining
reciprocating or a rotary-type principle: Either the
tool or the work reciprocates or rotates as Welding is the fusion or uniting of metal parts by
indicated. The planer is an example of heat and pressure. Soldering and brazing
reciprocating machine, since the work operations are similar except that the parts are
reciprocates past the tool, which is held in a joined by introducing a different metal between
stationary position. In other machines, such as the two in a molten state. Sintering applies to the
the shaper, the work is stationary and the tool bonding of metallic particles by the application of
reciprocates. Rotary machines are exemplified by heat. Structural adhesives in the form of powder,
the lather, which has the work rotating and the liquids, solids and tapes are widely used in the
tool stationary. In the drill press it is the tool that joining of metals, wood glass cloth and plastic.
rotates.
2.5 Processes used to change the physical
In ultrasonic machining, metal is removed by properties. There are number of processes in
abrasive grains which are carried in a liquid and which the physical properties of he material are
bombard the work surface at high velocity. The changed by the application of an elevated
velocity is generated by means of an ultrasonic temperature or from rapid or repeated stressing
generator. For electrical discharge and electro of the material. Processes in which properties are
arc machining, special arcs are generated that changed include:
can be used to machine any conducting material.
The optical laser is a strong beam of photons that Heat Treatment Hot Working
can be used to generate extremely high Cold Working Shot Peening
temperature and thus cut or weld metal.
280
CHAPTER 14 - MANUFACTURING PROCESS
Heat treating includes a number of processes lubricant that stands up under such tremendous
that results in changing the properties and pressures.
structure of metals. Although both hot and cold
working are primarily processes for changing the Dies must be hard and wear-resistant as well as
shape of metals, these processes have strong. They are made of children iron, hardened
considerable influence on both the structure and alloy steel, cemented carbide and diamond.
the properties of the metal. Shot peening renders
many small parts, such as springs, resistant to 3.4 Electro-Forming — Is one of the special
fatigue failure. processes for forming metals. Parts are produced
by electrolytic deposition of metal upon a
Section 3.0 Processes conductive removable mold or matrix. The mold
established the sizes and surface smoothness of
3.1 Brazing A group of welding operation in which
—
the finished product. Metal is applied to the
a non-ferrous filler metal melts at a temperature conductive mold, from electrolytic solution in
below that of the metal joined but is heated above which a bar of pure metal acts as an anode for
425°C. The molten filler metal flows by capillarity the plating current. It is particularly valuable for
between the heated but unmelted adjacent or fabricating thin walled parts requiring a high order
overlapping joint members or is melted in place of accuracy. Internal surface finish and
between these members. complicated internal forms that are difficult to
cure or machine.
Filler metals are divided into two classes: copper
aNoys and silver alloys. 3.5 Explosive Forming —An excellent method of
utilizing energy at a high rate, since the gas
Copper alloyed with zinc, tin, nickel, phosphorous pressure and rate of detonation can be carefully
or silver is brazed at 705°C to 175°C. controlled. Both low and high explosives, known
as cartridge system, the expanding gas is
Silver alloyed with copper, zinc, tin, calcium, confined and pressure may build up to 7042
manganese, nickel or phosphorous is brazed at . High explosives which need to be
2
kg/cm
635°C to 843°C. confined and which detonate with a high velocity
may attain pressures of up to 20 times that of
3.2 Blow Molding Is used primarily to produce tin
—
flow liquid set up intense shock waves that pass
walled hollow containers from thermoplastic through the medium between the change and the
resin. A cylinder of plastic materials, known as work piece but decrease in intensity as the waves
parison, is extruded as rapidly as possible and spread over more areas.
positioned between the jaws of a split mold. As
the mold is closed, it pinches off the parison and 3.6 Electroplating Electroplating is done on all the
—
the product is completed by air pressure forcing common metals and even on many metal after
the materials against the mold surface. their surfaces have been prepared. The piece to
be plated is immersed in a water solution of salts
3.3 Cold Drawing — Hot rolled stack is descaled, of the metal to be applied and made the cathode
cleaned and prepared for drawing. A common in a direct current circuit. Anodes of the coating
way of treating steel is to immerse it in hot metal replenish the solution when the current is
sulphuric acid, rinse, coat with lime and bake. flowing and ions of metal are attracted to the
The leading end of a piece is tapered for insertion work piece to form the coating. The rate of
through the die. A piece is pulled though a hole deposition and the properties of the plate such as
of a smaller size and emerges corresponding hardness, uniformity and porosity depend upon
reduced in size wire is pulled by being wound on getting a proper balance among the composition
a drum as it comes out of the die. Rods, bars of the plating solution, current density, agitation,
and tubes are pulled in a straight line by solution acidity and temperature.
mechanical means. A mandrel is inserted in a
tube to control the size of the inside diameter. 3.7 Extrusion Many plastics are extruded into long
—
281
CHAPTER 14— MANUFACTURING PROCESS
maybe of steel, aluminium, copper, bronze or performed in furnaces, ovens and kilns.
other metal. A piece of hot stock is placed in
the cavity on one side of the die. The a. Furnace, smelting and reduction melting and
machine is stripped, closes the two halves of refining heat treating, brazing and soldering,
the die to grip the stock, pushes the punch heating for hot working, boiler furnaces and
into upset the stock, retract the punch and incinerators.
282
CHAPTER 14— MANUFACTURING PROCESS
b. Kiln, cement kiln, lime kiln, ceramic kiln and d. Mounting —Accident and breakages occur
drying kilns. when wheel are mounted on unsuitable
apparatus or spindle end of buffing
c. Oven, drying and caring, baking, decorating machines. The spindle should be of adequate
and solvent evaporation. diameter but not be large as to expand the
center hole of the wheel; flanges should be
The automatic controls that regulate fuel and not less than one-third the diameter of the
air supply and ensure the correct wheel and made of mild steel or of similar
temperature should be maintained in good materials.
conditions, these controls should be
calibrated at frequent intervals. e. Speed The maximum permissible operating
—
283
CHAPTER 14— MANUFACTURING PROCESS
a. RoIling the steel into intermediate shape- 3.18 Riveting Mechanical means of permanently
—
blooms, billet and slabs fastening parts together to rivet two parts, a rivet
is put through a hole and its head placed on an
b. Processing blooms, billets and slabs into anvil. A punch with a hollowed end mashes the
plate, sheets, structural shapes or foils stem to close the rivet. Some rivets are hollowed
and their edges are curled outward.
The steel remains in ingots molds until the
solidifications are about to complete when the 3.19 Sizing — Product requiring close tolerance may
molds are removed. While still hot, the ingots are necessitate a final operation such as repressing
placed in gas-fired furnaces called soaking pits the part in a die similar to the one for compacting
where they attain or remain until they have it. Such sizing is a cold working operation that
attained a uniform working temperature of about improves surface hardness and smoothness as
1 200°C throughout. The ingots are then taken in well as dimension accuracy.
the rolling mill where, because of the large variety
284
CHAPTER 14- MANUFACTURING PROCESS
3.20 Stretch Forming — In forming a large thin metal most cases the effect of the heating is complete
involving symmetrical shape or double curve in a very short time. Furnaces for sintering may
bends, a metal stretch press can be used either be by batch or continuous type.
effectively. A single die mounted on a ram is
placed between the slides that grip the metal 3.22 Soldering —Uniting of two pieces of metal by
sheet. The die moves in a vertical direction and means of a different metal which is applied
the slides move horizontally large forces of 50 to between the two in a molten state. The metal for
150 tons (0.5 to 1.3M) are provided for the die this purpose is a low-melting alloy of lead and tin.
slides. The process is a stretching one and
causes the sheet to be stressed above its elastic SOLDERING
limit while conforming to die shape. This
accompanied by a slight thinning of the sheet and Hard Soft
action is such that there is little spring back to the
metal once it is formed. I I
Brazing Silver Soldering Soldering Iron Wiping
321 Sintering — Application of heat, which must be
kept at a temperature below the melting point of 3.23 Thermo-Forming Consists of heating a
—
the metal powder, in the production of thermo-plastic sheet until it softens and then
commercial products from metallic powders by forcing it to conform to some mold either by
pressure or atomic forces, and resulting in the differential air pressure or mechanical means.
bonding of fine particles together, thus improving
the strength and other properties of the finished 3.24 Ultrasonic Machining A mechanical process
—
product. Products made by powder metallurgy was designed to effectively machine hard brittle
are frequently mixed with different metal powders materials. It removes materials by the use of
or contain non-metallic constituents to improve abrasive grains that are carried in a liquid
the bonding qualities of the particles and between the tool and the work and bombard the
improved certain properties or characteristics of work surface at high velocity.
the final product. Cobalt or other metal is
necessary in the bonding of tungsten carbide 3.25 Wire Drawing Wire is made by cold drawing
—
particles, whereas graphite is added with bearing- hot rolled wire rod through one or more dies to
metal powders to improve the lubricating qualities decrease its size and increase the physical
of the finished bearing. Sintering is an operation properties. The wire rod, about 6 mm in diameter,
in which the particles are fused together in such a is rolled from a single billet and cleaned in an
way that the density is increased. During the acid bath to remove scale, rust and coating. The
process grain boundaries are formed which is the coating is applied to prevent oxidation, neutralize
beginning or recrystallization. Plasticity is any remaining acid and to act as a lubricant or a
increased, and better mechanical interlocking is coating to which a later applied lubricant may
produced by building a fluid network. The cling.
temperatures used in sintering are usually well
below the melting point of the principal powder 3.26 Welding and Thermal Cutting — The three
constituent but may vary over a wide range up to common direct source of heat are:
a temperature just below the melting point Tests
.
have proved that there is usually an optimum a. Flame produced by combustion of fuel gas
sintering temperature for a given set of with air or oxygen.
conditions.
b. Electrical arc, stwck between an electrode
For most metals, sintering temperature can be and a work piece or between two electrodes.
obtained in commercial furnaces, but for some
metals requiring high temperature, special c. Electrical resistance offered to passage of
furnaces must be constructed. There is current between two or more work piece.
considerable range in the sintering temperature,
but the following temperatures have proved Types of Welding:
satisfactory: 1 095°C for iron, 1 180°C for
stainless steel, 870 for copper and 1 480°C for 1. Gas Welding
tungsten carbide. Sintering times range from 20 2. ArcWelding
to 40 minutes for the above listed metals. The 3. Atomic Hydrogen Welding Welding
time element varies with different metals, but in 4. Electro-Beam Welding
5. Electro-Slug Welding
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CHAPTER 14— MANUFACTURING PROCESS
6. Flash Welding
7. Friction Welding 5. Electro-SIug Welding The work piece
—
8. Laser Welding and Drilling are usually set vertically, with a gap
9. Metal Spraying between them and copper plates or
10. Plasma-Arc Welding shoes are placed one or both sides of the
11. Resistance Welding joint to form a bath at the bottom of which
12. Spark Erosion Machining an arc is established under a flux lager
13. Stud Welding between one or more continuously fed
14. Thermal Welding electrode wires and a metal plate.
1. Gas Welding — The process in which 6. Flash Welding (Butt Welding) —The
gases are used in combination to obtain two metal parts to be welded are
a hot flame. Commonly used are connected to a low voltage high current
acetylene, natural gas, hydrogen in source. When the end of the components
combination with oxygen. The maximum are brought into a contact, a large current
temperature developed for oxy-hydrogen flows causing flashing to occur and
welding is 1 965°C for Oxy-acetylene bringing the end of the components to
Welding is 3 440°C. welding temperature.
wherein the metal is heated to its liquid purely mechanical welding technique in
state and allowed to solidify thereby which one component remains stationary
making the joint. Heating is achieved while the other is rotated against it under
through an electric arc between an pressure. Heat is generated by friction
electrode and the work pieces. The high and at forging temperature the rotation
current low voltage power source can ceases. A forging pressure then affect
either be an AC or DC. the weld.
The plain electric arc welding 8. Laser Welding and Drilling Laser
—
286
CHAPTER 14- MANUFACTURING PROCESS
current, pressure by the electrodes the atmosphere that normally results to inferior
produces a forge weld. quality weld joints. Shielding can be
accomplished by various means such as inert
12. Spark Erosion Machining In this — gases, welding fluxes but the most common is by
technique metal is removed from the the use of readily available coated electrodes.
piece to be machined by the action of Refer to the illustrative drawing, Fig. 14.4.1
electric discharges between the piece below:
and an electrode immersed in electrolyte
oil.
4.1 Welding Process and Electrodes For welding mild steel and low alloy steels, the
weld metal must match the metallurgy of the base
As previously discussed, this is a development of metal. The selection of the right electrode,
the early electric arc welding. The main therefore, shall be given a very thorough
improvement is the introduction of shielding for consideration. The American Welding Society
the molten weld metal against contamination from (AWS) and the American Society for Testing
287
CHAPTER 14- MANUFACTURING PROCESS
Refer to Table 14.4.1 for various Electrode a. Tensile Test A test specimen is cut-out
—
Classification. After the above number series, from the work piece and stretched to failure.
additional suffix maybe added to denote Ultimate strength, yield point and percent
electrode composition. Refer to Table 14.4.2 elongation can be determined.
4.2 Common Weld Defects b. Bending Test A test specimen is cut out
—
weld heat affected zone (HAZ) due to brittle 4.5 Non Destructive Testing (NDT)
weldments associated with stresses. This is
common in welding molybdenum and This is a process wherein weld examination is
chromium alloys and thick weldments. This done without destroying the material. Random or
can be minimized by pre-heating and complete examination of all welds can be done
corrected by either stress relieving or and the material can still be used.
annealing.
a. Dye Penetrant Examination — This can be
c. Pinholes —These are small holes through determine surface cracks and porosities
the weldments normally caused by gas which may not be readily seen. This is done
bubbles escaping through the molten weld by thoroughly cleaning with solvents the weld
metal while cooling. This is commonly due to joint and spraying the surface with a
moisture loaded electrodes or dirty/moist penetrating dye, normally red. Allow the dye
base metals. to penetrate for about one minute and
thoroughly wipe it off the surface and
d. Porosity — These are gas bubbles or minute followed with a gentle spray of a developer,
impurities trapped in the weldment normally normally white. The whole surface will
due to dirty or moist electrode or become white except in areas that previously
contaminated base metals. absorbed the dye wherein the defect will be
revealed.
288
CHAPTER 14— MANUFACTURING PROCESS
Basic Application
Position Supply Effect
Production Welding
Especially recommended for single pass, high speed, high current,
DC
— horizontal fillet welds. It is characteris-tically easy to handle and
EXX 12 All Mild Medium useful in cases of poor fit-up, both groove and fillet, where a wide
AC
range of currents is used. Class 12 has reduced penetration but can
meet radiographic standards with single pass welds.
n iron powder type electrode ideal for fillet welds. The iron powder in
AC he electrode coating assists in increasing the deposit rate over the
EXX 24 H.F. — F.
(DC
- Mild Light 12 class. Electrode can be used in drag technique with ease of
handling and good weld appearance. Requires better fit-up than 12,
but is of similar application, although limited as to position.
EXX27 H.F. - DC — s 50% faster than the 20 electrode. It is primarily a downward deep
F Mild Medium troove rod, well suited for heavy sections. Second only to 24 in
AC
velding speed, but with properties superior to it. Both are equally
asy to handle.
apable of higher deposition rates than 20. Designed for welding of
EXX3O DC—
F Mild Medium heavy plate in the flat position and good in deep groove welding. Has
A
less fluid slag than 20.
Current supply in parenthesis, as (C +), indicates that, for production H.F. = Horizontal Fillet Position
welding, some sacrifice in advantages must be made using the F. = Flat Position
designated supply.
289
CHAPTER 14- MANUFACTURING PROCESS
Table 14.4.2
Electrode Composition
XX 10 Al 0.35—0.60 0.40
XX 11 Al 0.35 0.60 0.40 —
10 Bl
11 Bl 0.35—0.60 0.40 0.04
13 Bi 0.10 0.40—0.65 0.40—0.65
15 Bi 0.45—0.90 0.60@ 0.04
16 Bl
10 B2
11 B2 0.35—0.60 0.40 0.04
13 B2 0.10 0.40—0.65 1.00—1.50
15 B2 0.45 — 0.90 0.60@ 0.04
16 B2
10 B3
11 B3 0.35 — 0.60 0.60
13 B3 0.12 0.90 — 1.20 2.00 — 2.50 0.04
15 B3 0.45—0.90 0.60
NICKEL STEEL ELECTRODES
15 Cl 0.12 2.00
16 Cl 0.12 0.90 0.60@ 0.04 2.75
15 C2 0.10 3.00
16 C2 0.10 3.75
@ The silicon content may be 1.00 maximum if the carbon content is restricted to 0.06 maximum.
CAUTION: It is important that this electrode selection procedure not be considered a final authority instead of
a series of actual weld trials or field experience. In cases of production welding, it is most
important that welding procedures or specifications be produced through experimentation.
Success and failure in high speed welding may still be in the proper selection of such variables as
amperage, voltage, speed of travel, electrode angle, welding technique, joint preparation, preheat,
inter pass temperature, post heat treatment, etc.
290
CHAPTER 14— MANUFACTURING PROCESS
current to create a magnetic field in a 5.2 Protective clothing, eye, nose, feet and hand
specimen with the magnetic particles (iron protection shall be used when exposed to hazard
powder) indicating where the field is broken such as toxic substances, radiation, hot and
by discontinuities such as cracks in the corrosive substances.
material. Applicable to ferromagnetic
materials only. 5.3 Automatic control that regulate fuel and air supply
should be maintained in good condition to ensure
d. Radiographic Examination This employs
-
the correct temperature for the process.
radioactive isotopes such as Cobalt-60,
lridium-192, Thulium-170 or Cesium-137 and 5.5 Substitution of toxic substances to non-toxic
radiographic films. The internal or external substances in any quantity process is possible.
properties of the work piece can be depicted
on the film by the passage of radiation 5.4 Sources of dangerous noise should be
through the work piece. This examination can acoustically enclosed.
reveal cracks, porosities, inclusions, lack of
penetration and other defects. With the film, a 5.6 Rest rooms shall be provided with proper
permanent record of the joint can be kept. ventilation and facilities.
Areas that need repairs can likewise be
pinpointed. 5.7 Pipe lines or hoses shall be properly color coded.
This needs a trained technician to safely 5.8 Uninsulated hot pipelines or ducts shall be
handle and operate the radio isotope. provided with guards or insulated at portions
adjacent to passage ways for personnel
e. X-ray Examination — Essentially the same protection.
with radiographic examination except only on
the source of radiation. This utilizes electricity 5.9 Moving machine parts shall be provided with
powered X-ray machine that generate adequate protective guards.
ionizing radiation.
5.10 Welders must wear protective clothing, welding
Also needs a trained technician to safely masks and gloves.
handle and operate the machine.
5.11 Operations involving radiations shall be properly
f. Ultrasonic Examination —This utilizes identified and barricaded. Only authorized
ultrasounds that penetrate most common technicians shall handle these equipment.
materials. The time of rebound of ultrasounds
from the probe which is pressed on one side
of the material to the other side or any
discontinuity is converted to unit of linear
Section 6.0 Pollution Control
measure. This method can detect 6.1 Air Pollution Control Equipment
laminations, cracks and inclusions. This
needs an expert to evaluate the findings.
a. To promote a clean environment,
4.6 Final Test of Completed Work manufacturing process or installation whose
operation results in the emission of
The completed work is normally tested for contaminants must be provided with
soundness by actual test loading. Particularly for appropriate air pollution control equipment.
291
CHAPTER 14- MANUFACTURING PROCESS
b. Air pollution control equipment for collecting constituents of a gas stream can be
particulate matter (smoke, dust, fumes, mists, removed or covered.
etc.) emission are:
3. Afterburners combustion converts the
—
292
CHAPTER 14- MANUFACTURING PROCESS
293
CHAPTER 14- MANUFACTURING PROCESS
294
I
CHAPTER 15— FUELS AND LUBRICANTS
Chapter 15
295
CHAPTER 15— FUELS AND LUBRICANTS
Table 15.2.1.1 Classification of Coals by Rank* Horizontal firing, employs a turbulent burner,
(FC = fixed carbon; VM = volatile matter. Btu British thermal units) which consists of a circular nozzle within a
Limits of Fixed Csrbori or
housing provided with adjustable valves, the unit
I Ph
Class Group Btiu (Mineral-matter-
R equisleysica
being located in the front or rear wall. The
primary air and coal are fed to the nozzle, in
I. Anthracitic 1. Meta-anthracite Dry FC, 98% or more which the mixture is given a rotary motion by
2. Anthracite
(dry) VM, 2% or less)
Dry FC, 92% or more
narrow, spiral vanes. The secondary air enters
and less than 98% (dry the outer housing through the adjustable vanes,
VM, 8% or less, and more
than 2% which provide rotary motion at an angle different
3. Semi-anthracite Dry FC, 86% or more,
and less than 92% (dry
Non-agglomeratingt
from that of the primary air and coal, the
VM, 14% or less, and meeting of the primary-air coal mixture at the
more than 8%
periphery of the nozzle, creates a high degree of
II. Bituminous f 1. Low-volatile
bituminous coal
Dry FC, 78% or more
and less than 68% (dry
turbulence. This type of burner is suited to high
VM, 22% or less, and capacity and dry bottom furnaces.
more than 14%
2. Medium-volatile Dry FC, 69% or more
bituminous coal and less than 78% (dry
VM, 31% or less, and
Corner or tangential firing is characterized by
more than 22% burners located in each corner of the furnace
3. High-volatile A Dry FC, less than 69%
bituminous coal (dry VM, more than 31%), and directed tangent to a horizontal, imaginary
4. High-volatile B
and moist § Stu, 14 000
Moist § Btu, 13 000 or
circle in the middle of the furnace, thereby
bituminous coal more, and less than 14 making the furnace the burner in effect, since
000
5. High-volatile C Moist Btu, 11 000 or more turbulence and intensive mixing occur where the
bituminous and less than 13 000
streams meet. The coal and primary air enter
Ill. Sub- 1. Sub-bituminous Moist Btu, 11 000 or Both weathering and
non-agglomerating ¶
through rectangular or square coal nozzles;
A coal more, and less than 13
bituminous
2. Sub-bituminous 000 secondary air is supplied partly around the
B coal
3. Sub-bituminous
Moist Btu, 9500 or more,
and less than 11 000
nozzles and partly through ports above and
C coal Moist Btu, 8300 or more, below them. Dampers proportion the secondary
and less than 9500
IV. Ligriitic 1. Lignite Consolidated air to the various sections. The relative velocities
2. Brown coal Moist Btu, loss than 8300
Moist Btu, less than 8300
Unconsolidated
of gas and fuel produce a scrubbing action that
promotes the transport of oxygen to the fuel,
*
This classification does not include a few coals that have unusual through the film of combustion products around
physical and chemical properties and which come within the limits of the particles. Further, the tangential motion of
fixed carbon or BTU of the high-volatile bituminous and sub- the gases produces a vortex, which effectively
bituminous ranks. All these coals either contain less than 48% dry,
mineral-matter-free fixed carbon or have more than 15 500 moist, lengthens the time that the combustible is in the
mineral-matter-free Btu. furnace. This type of firing is suited to either wet
t If agglomerating, classify in low-volatile group of the bituminous or dry-bottom furnace operation or medium or
class.
Moist Btu refers to coal containing its natural bed moisture but not high volatile coals, and it is capable of extremely
including visible water on the surface of the coal. high capacities.
§ It is recognized that there may be non caking varieties in each
group of the bituminous class.
¶ There are three varieties of coal in the high-volatile C bituminous 2.5 Furnace Heat Release and Heat Available.
group, namely, (1) agglomerating and non-weathering, (2) Furnaces for pulverized coal firing are designed
agglomerating and weathering, and (3) non-agglomerating and non either to remove the ash as molten slag
weathering.
intermittently or continuously (wet bottom), or as
Occasionally, the admission of secondary air dry ash (dry bottom). Wet-bottom construction
along the front walls is used with considerable generally is chosen for low-grade coals that
success, particularly in connection with very low- have low fusion characteristics, whereas dry-
volatile coals, which require long flame travel, bottom construction often is selected for high-
or in high, narrow furnaces. fusion coals. Experience has shown, however,
that it is possible to design reliable dry-bottom
Impact firing, a form of vertical firing, consists of units to burn any grade of coal available, at high
burners located in an arch low in the furnace or boiler availability. Pulverized-fuel firing is used
in the side walls and directed toward the furnace for steam capacities ranging from 23,730 to
door, with high velocities of both primary and 454,550 kgs. per hr. capacities above 68,180
secondary air. This type of firing is used kgs. per hr. being almost exclusively fired with
exclusively in wet-bottom or slagging type pulverized coal. The furnace heat release varies
3 per hr.
from 558,662 to 1,117,224 kilo Joules/m
furnaces.
782,071 to 819,313 kJ for best performance of
wet-bottom furnaces or for dry-bottom units
296
CHAPTER 15- FUELS AND LUBRICANTS
t Ash and sulfur shall be reported to the nearest 0.1% by dropping the second
decimal figure when it is 0.01 to 0.04, inclusive, and by increasing the percentage
by 0.1% when the second decimal figure is 0.03 to 0.09, inclusive. For example 4.85
to 4.94%, inclusive, shall be considered to be 4.9%.
J Ash-softening temperatures shall be reported to the nearest 10 F. For example,
2,635 to 2,644 F, inclusive, shall be considered to be 2,640 F.
§ For commercial grading of coals, with ash less than 2%, ranges in the percentage
ash smaller than 2-4 are commonly used.
value ranges from 14,800 to 15,500 Btu/Ib. In bituminous coal 13,000 to 15,500
Btu/Ib. In liquates, it may be as low as8 300 Btu/lb. See also Table 15.2.1.2(a) for
Quality of coals in the Philippines.
Note: °C
Section 4.0 Wood and Hogged Fuel
= (°F 32) + 1.8
-
kg lbs+2.2
4.1 Wood fuel may come to the boiler plant in the
M = ft.+3.28
form of cordwood, slabs, edging, bark, sawdust,
kilo Joules (kJ) = BTU x 1.055
or shaving and frequently several forms are
297
CHAPTER 15- FUELS AND LUBRICANTS
Table 15.2.1.la
Quality of Major Coal Fields in the Philippines
(Air-Dried Basis)
Calorific Volatile Total Fixed Ash Total Coral Fields
.
Coral Fields Value (BTU/LB) Matter (%) Moist (%) Carbon (%) % s (%)
Sub-bituminous
10500—11 300 35—37 6—10 42—47 2—7 1.5—3
East Sub-bituminous
9100—11 000 30—35 11 —14 1—6 1—6 0.3—1.3
West
Bituminous
POLILIO ISLAND
NOTE: kg lb + 2.2
Kilo Joules (KJ) = BTU x 1.055
o
Cl) 4
fi —
298
CHAPTER 15— FUELS AND LUBRICANTS
299
CHAPTER 15— FUELS AND LUBRICANTS
300
CHAPTER 15— FUELS AND LUBRICANTS
301
CHAPTER 15— FUELS AND LUBRICANTS
given burner equipment. The Say bolt Section 7.0 Storage and Handling of Fuel
Universal viscosimeter is used for low Oil
viscosity fuel oils, and the Say bolt Furol
viscosimeter for heavier oils. Other types 7.1 Fuel Oil Storage Tanks — generally are
of viscosimeters for fuel oils are the classified by material, as steel or concrete; by
Redwood and Engler. size, as gallons, etc; by location, as exposed or
inside, underground or buried; and by use, as
6.3 Firebrick and Refractory Cement. Firebrick light or heavy oil tanks. The essential
and refractory cements should be selected on requirements for tanks are tightness and
the basis of the service in which they are used. durability. The following specifications are
A grade higher than absolutely necessary generally accepted standards. Local regulations
should be chosen because of abuse under should be studied before installation. Tanks for
extreme operating conditions. The life is heavy oil usually have a manhole and provision
refractory material in combustion chambers is for a tank pre-heater, using either steam or hot
shortened by sustained high temperature, by water. Such tanks should be designed to heat
rapid changes in temperature, and by panting or the oil in the vicinity of the suction pipe to not
vibration from combustion. High temperatures over 37.7°C.
result from operation above normal rating,
normal operation with insufficient combustion a. Capacity and Location of Tanks. The
chambers designed for high heat releases. location of a tank with respect to distance
Rapid temperature changes may be reduced to from tank shell to line of adjoining property
the minimum by the operating personnel. A cold or nearest building depends on the
boiler should be brought up to operating construction, contents, equipment, and
temperature and pressure as slowly as possible. greatest dimension (diameter, length, or
When taking the boiler out of service, registers height) of the tank and should be in
and dampers must be closed tightly to allow the accordance with Table 15.7.1.1
boiler to cool slowly. Panting is usually due to
improper drafts, faulty atomization, fluctuating oil The minimum distance between shells of
pressure or high heat releases. Sputtering any two all-steel, gas tight tanks should be
results from water in the oil or wet steam not less than one-half the greatest
supplied to steam-atomizing burners. dimension (diameter, length, or height) of
the smaller tank except that such distance
6.4 Furnace Floors. The burners’ manufacturer should not be less than 9910 mm; for tanks
usually specifies the furnace floor construction. of 68 130 litres or less, the distance need
The several layers are as follows: (1) insulating not exceed 915 mm.
brick or material; (2) first course of brick, dry,
laid 1.6 mm apart to provide for expansion joints Tanks should be so located as to avoid
broken between adjacent rows; (3) dry refractory possible danger from high water.
cement, filling all cracks and covering bricks to
depth of 3.17 mm; (4) second course of brick When tanks are located on a stream without
similar to first, overlapping joints in first course; tide, they should, where possible, be down
and (5) day refractory cement as in (3). After stream for burnable property.
firing, the bricks take a permanent set and the
cement vitrifies to a hard surface. For airports b. Fill Lines. Not less than 50 mm pipe should
built into the floor, the bricks may be set in be used for light oils (No. 1); for heavy oils
refractory cement mortar. (No. 6), 150 mm or 200 mm pipe should be
used. A pipe too large is better than one too
6.5 Metal Combustion Chambers. For wet-base small. The fill line for any storage tank
domestic heating boilers and forced warm air should pitch from the fill box to the tank. A
furnaces, stainless steel combustion chambers trap should be provided, either directly
are used extensively. Type 430 stainless steel inside or outside of the tank, or the fill line
(17% chromium) is representative of the lowest- sealed by ending it in the tank below the
grade material that may be used for this service. bottom of the suction line. The fill line
always should be connected at the low end
of the tank and never cross-connected to
the vent pipe.
302
CHAPTER 15— FUELS AND LUBRICANTS
Floating_Roof Building
*Top of underground tanks to be not less than 305 mm Group A for Yes Not less than
underground. Material to be galvanized steel, basic open- refined greatest
hearth, or wrought-iron. Joints to be welded, or riveted and petroleum dimension
caulked. When the tank is installed inside buildings without products not (diameter,
enclosure, the maximum capacity is 1 040 litres and the subject to length, or
minimum thickness of 1.984 mm. boil- over height);
Note: maximum
litres = gals. X 3.785
mm = inch x 25.4 distance
2 = Pounds/sq. Foot x 4.88
kg/rn required, 37
..metre
Table 15.7.lb Group B for Yes Not less than 1
Specifications for Above ground Oil Storage Tank refined 1/2 times the
303
CHAPTER 15— FUELS AND LUBRICANTS
Compounds other than hydrocarbons occur 8.3 Kerosene is defined as a petroleum distillate
-
in only very minor proportions in gasoline. having a flash point not below 22.8°C as
Tetraethyl lead is often present, usually as determined by the Abel tester (which is
approximately equivalent to 22.8°C as
an anti-knock compound in concentration
not exceeding 3 cc per gal or motor determined by the Tag closed tester, ASTM
gasoline. Sulfur compounds of non corrosive standard method D56) and suitable as an
properties may be present, since sulfur illuminant when burned in a wick lamp.
compounds occur in crude oil, but their
concentration in gasoline rarely represents a Typical kerosene have the following ranges of
content of sulfur greater than 0.1% by properties: distillation, 160 to 287.8°C. API
weight. When stored for a long time, gravity, 40 to 48 degrees; Tag flash 43.3 to
gasoline may form organic peroxides up to 54.4°C, Kinematic viscosity at 37.7°C 1.4 to 2.0.
about 200 parts of active oxygen per million Other properties are listed in Table 15.8.4
parts of gasoline, and resinous polymers,
called gum, up to about 30 mg. per 100 cc Even in areas where electrification has made
of gasoline. Many commercial gasoline kerosene lamps obsolete, kerosene has
contain minor concentrations of continued to be an important fuel for heating
antioxidants, and some contain solvent oil to purposes, being consumed in wick type and
guard against the deposition of gum. various vaporizing-type burners in stoves,
Commercial gasoline on the market are
304
CHAPTER 15— FUELS AND LUBRICANTS
1.8
heaters, and furnaces. In such cases, the
product is frequently known as range oil. The Article 15.9 Other Liquid Fuels
specifications for No. 1 fuel also include Table 15.8.4 Specific Volume and Other Properties
products of the kerosene type. of Gasoline and Kerosene
305
CHAPTER 15— FUELS AND LUBRICANTS
Chemical composition C
8
H
3 C
1
H
4 0
the destructive distillation of bituminous coal
Boiling point, °F -43.8 +31.1
carried out at high temperature. A typical
Specific gravity, liquid, at 60/60 F 0.508 0.584
composition of tar is: C, 86.7%; H, 6.0%; N,
0.1%; S, 0.8% 0, 3.1%; ash, 0.1%; water, 3.2%. Specific gravity, vapor, at 60 F, 14
psia (air = 1) 1.522 2.006
The black color is due to free carbon in
suspension (about 4%). The high heating value Specific heat, vapor, at 14 psia,
Btu/Ib, cy 0.390 0.396
equals 37,925 kJ per kg. The viscosity is about
140 Say bolt sec at 60°C. Coal tar weighs 1.14 Specific heat, vapor, at 14 psia,
Btu.lb, cx 0.346 0.363
kg per liter. This analysis shows tar to have
almost the same chemical composition as the Heat of vaporization, at 14 psia,
Btu/lb 183 166
combustible matter of the coal from which it is
Weight, lb/gal 4.23 4.86
made. Tar is used principally in reheating 31.8
Vapor produced, cu ft/gal 36.5
furnaces and open-hearth furnaces of steel
Heat content, gross Btu/lb 21,690 21,340
works. It is not easily obtainable in the open
Explosion limits, % in air (lower) 2.0—2.4 15.-1.9
market. Since it is by-product, its price is more
Explosion limits, % in air (upper) 7.0-9.5 5.7-8.5
or less arbitrary. 15.4
Air required for combustion, lb/lb 15.6
8.7 Liquefied Petroleum Gases (LPG) are of fuel
mixtures of hydrocarbons liquefied under
pressure for efficient transportation, storage, VAPOR PRESSURE of LP-Gases
and use. They are generally composed of
ethylene, propane, propylene, butane, 250
isobutene, and butylenes. Commercially, they
are classed as propane, propane-butane
mixtures, and butane. They are odorless,
colorless, and non-toxic. They should always be 200
odorized so that leaks may be detected long
before the lower explosion limit of the gas-air
mixture is reached. These gases are heavier
than air and seek ground level. If leaks will result
150 ro/
if dangerous accumulations collect and are not
dispersed by wind or other means, an automatic
shut-off safety device shall be installed to 100
protect the LPG pipe lines after the regulator in
rigid piping lines and before the flexible
connection to each burner. Liquefied petroleum 50 But ne —
gases are derived in most part from gases
produced in petroleum refining operations and 120
40 -20 0 20 40 60 80 100
also in substantial quantities from natural gas.
The sulfur content is generally low particularly in
gases produced from natural gas. Butane is not
used as extensively as propane for two reasons:
(1) its relatively high boiling point makes it The distribution and uses of LP gases have
necessary to add external heat when the expanded very rapidly. The uses include
temperature drops below 0°C; and (2) butane domestic water heating, cooking, refrigerating,
has high economic value in the manufacture of and space heating. In small communities the
synthetic rubber and for high octane gasoline. gases are distributed from a central point in
The physical properties of propane and butane place of manufactured gas. They are also used
are given in Table 15.9.3. in the gas industry for enriching manufactured
gas and as a stand by supply. Commercially and
industrially, they are used as a fuel for internal
combustion engines and for any of the various
306
CHAPTER 15— FUELS AND LUBRICANTS
application where manufactured or natural gas Fuel-Oil Price varies with many factors; one of
might be used. them is quality. High-quality distillate fuels are
more expensive than residual or blended fuels.
LP gases are stored in portable and semi- High demands for gasoline and heating fuels
portable cylinder containing up to 45.45 kg. of indicate advisability, from the stand point of fuel
liquid, and in above or below-ground storage cost, of using the lowest suitable grade of diesel
tanks with capacities up to 30,000 gal. All fuel available. However, lower fuel cost must be
storage installation should be made in balanced against increased operating and
accordance with the requirements of local maintenance costs. Always start from engine
authorities. Cylinders should be constructed to builder’s specifications and depart from them
meet the requirements. Storage tanks should be only slowly and cautiously. Specifications are
constructed and tested in accordance with the important in preliminary judgment of fuels, but
requirements of the PSME codes for unfired the final criterion is acceptance of a fuel by the
pressure vessels. diesel engine itself.
Section 9.0 Diesel Fuel Oils 9.2 Specifications. Terms usually employed in
diesel-fuel specifications are:
Diesel engines in general are capable of burning a
rather wide variety of liquid fuels; the large-cylinder Specific Gravity, seldom used, compares the
slower-speed diesels will burn a wider range than the weight of the fuel with water; it is expressed as a
smaller engines. While vegetable and animal oils have decimal, with water taken as 1.0. The term API
been used to a limited extent, the most available and (American Petroleum Institute) gravity is
cheapest liquid fuels are mineral oils, usually frequently used. Water is taken as API 10
derivatives of crude petroleum. degree. Oils lighter than water have higher
degrees API gravity, according to the formula.
9.1 Classification. Refiners grade fuels broadly
according to methods of production: (1) Distillate API degree = 141.5 -131.5
fuels are produced by distillation of crudes. Specific gravity at 60 F
Various grades are distinguished according to
choice of initial and final boiling points used in Heat Content is expressed in Btu per
the process. (2) Residual fuels are those left second pound higher heating value. Fuel
after the distillation process. (3) Blended fuels oil usually is purchased by the gallon, and
are mixtures of straight distillate fuels with the heavier fuels (low API gravity) have
cracked fuel stocks. Cracked stocks are the lower cost per unit of heating value.
residuals of fuels which have been treated
thermally or catalytically to obtain yields of Note: kJ = BTU x 1.055
lighter-grade fuels or gasoline. kg = Ibs+2.2
Lightest grade distillates, classed as kerosene Flash Point is the temperature at which the
—
or No. 1 fuel oil, may have an initial boiling point fuel gives off vapors ignited by an open flame
of 176.6°C and end point of 260°C. Heaviest and is significant only from handling and storage
grades of distillates, classed as No. 3 or 4 fuel standpoints. Usually a flash point of 65.22°C
oil, may have initial boiling point of 232°C to meets all fire, insurance, and transportation
260°C and end point of 343°C to 371°C. regulations.
Refiners may produce several grades of
distillates fuel and usually try to produce fuels Pour Point is important only for handling and
—
from the available crudes which will satisfy both storage reasons. Heating coils in storage tanks
domestic heating use and diesel engine make possible the use of high point fuels in cold
requirements with least number of grades. weather.
Residual fuels, No. 4 or No. 5, are suitable only Viscosity — is measure of resistance to flow.
for the slower-speed diesel. Residual and Important from the standpoint of handling
blended fuels have wide variations in through piping, especially in cold weather, and
characteristics and suitability for diesel use and very important for injection characteristics. High
each must be evaluated separately. viscosity fuels do not atomize as freely and may
upset combustion results in the engine.
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CHAPTER 15— FUELS AND LUBRICANTS
measures vaporizing tendencies and is usually the most important characteristics of a fuel. The
expressed in distillation-range temperatures , term is used to express the speed at which
sometimes as temperatures at which successive combustion starts and continues under service
10% increments of the fuel are distilled. conditions. When fuel is injected into a diesel
engine cylinder, there is a delay until a portion of
Cleanliness — Contamination such as water, the fuel ignites. The burning increases the
abrasives, gummy constituents, pipe or tank temperature and promotes general ignition and
scale, or sludge must be eliminated. The usual combustion. If ignition quality is low and engine
BS and W (bottom sediments and water) limit is speed is high, a large part of the fuel charge is
0.05% maximum when the engine is equipped injected before any appreciable ignition occurs.
with fuel filtration facilities. In large stations, with Hence, at the time of ignition, there is so much
special filtration equipment, a limit of 1 to 2% is fuel present that combustion takes on the
advisable. characteristics of an explosion, causing rough
running.
Ash Content includes non-combustible
—
mineral materials, abrasive in action in engine Cetane Number — The usual method of
cylinders, must be limited to less than 0.01% in expressing ignition quality is the determination
slower-speed engines. of delay angle of the fuel in a standardized test
engine. The delay angle is the angle of cranks
Corrosion — Fuel should be non-corrosive by shaft revolution between the beginning of fuel
test, but this may not correlate with corrosion of injection and the first appreciable rise in
fuel-system parts. Acidity and alkalinity test are pressure due to combustion. This is expressed
not normally specified or distillate fuels because by cetane number. Cetane is a hydrocarbon
manufacturing process produces neutral fuels. fluid of high ignition quality. It is mixed for trials
All fuels should be neutral in reaction, and with alphamethylnaphthalene, which has a poor
crudes or heavy fuels should be tested. ignition quality. After determination of the delay
angle of the fuel being tested, the performance
Sulfur may be present in many forms, some
—
is duplicated, using a mixture of these two pure
corrosive and some non corrosive. Products of compounds, and employing the trial-and—error
combustion of sulfur containing fuels are likely to method. The cetane number is the percentage
be corrosive or cause deposits in engines. In of cetane used in the mixture.
general, small engines have operated
satisfactorily on fuels containing as much as 1% Fuels with high cetane numbers give smooth
total sulfur, whereas large slow-speed units combustion and provide easy starting. The
have operated on fuels with as much as 3% slower the engine speed, the less the
sulfur. importance of the cetane number.
Carbon Residue — is sometimes called Diesel index is also used to express ignition
Conradson carbon. It is the carbonaceous quality of fuels:
residue remaining after destructive distillation,
expressed in percentage by weight of the Diesel index = API gravity x Aniline cloud point
original sample. In light fuels, a test is run on the 100
10% remaining after the lightest 90% has been
distilled off. This is called “carbon residue on Both gravity and aniline cloud point are related
10% bottoms”; it gives values about ten times to fuel composition, hence to ignition quality.
those obtained from the entire sample. Higher- Diesel index and cetane number can be fairly
speed engines function most satisfactorily on well correlated.
fuels having carbon residues on 10% bottoms of
0.25% or less, whereas some large low-speed Another method of expressing ignition quality is
engines have used fuels with much higher by the empirical cetane number determined by a
carbon residues. This test believed to indicate chart that takes into consideration a number of
the tendency of a fuel to form carbon deposits in factors (including gravity, viscosity and volatility)
an engine, but correlation between tests and related to fuel composition.
actual engine results is not always good.
In the range of 50 to 60, the diesel index is
normally 5 to 10 points higher than the actual
308
CHAPTER 15 — FUELS AND LUBRICANTS
cetane number. In the range of 35 to 45 diesel storage facilities are needed on the
index closely approaches cetane number. Below premises of the consumer if the gas is
30, diesel index is usually somewhat lower than furnished by a public utility.
cetane number. The correlation between
empirical cetane number and actual cetane b. Gas Analysis. In ordinary methods of gas
number is generally similar, but the results are analysis, the gas passes through a series of
more consistent than those obtained from the absorbents, each of which removes a
diesel index. districts components or group of
components. The remainder of the gas is
Additives (amyl nitrate, etc) improve the ignition subjected to combustion with oxygen or air.
quality of fuels but add to the fuel cost. Engine Measurements are made on a volume basis,
tests alone are used for determining the ignition and the results are expressed in
quality of additive-improved fuels. percentages, on a dry basis, even though
the actual sample may have saturated with
9.3 Fuel Selection. Wide and numerous variations water vapor. Most of the equipment
in engine design, such as size of cylinder, speed available for absorption methods of analysis
of revolution, form of combustion chamber, and provides for determining CD , illuminants,
2
injection system, affect fuel requirements. In 02 CD, H , CH
2 , C
4 , and N
H
2 2 in the order
selecting fuel oils, follow the engine builder’s listed, CO
2 is absorbed in a sodium or
specifications but permit the fuel supplier as potassium hydroxide solution; illuminants in
much latitude within them as possible. sulphuric acid, bromine water, or cuprous
Restrictive specifications increase the fuel price. beta-naphthol; 02 in alkaline pyrogallate or
Increasing the cetane number above the chromous chloride; CO in acid or alkaline
minimum required for smooth running does not cuprous chloride, cuprous sulphate beta —
309
CHAPTER 15— FUELS AND LUBRICANTS
310
CHAPTER 15— FUELS AND LUBRICANTS
a. Viscosity Index - indicates the relative In food processing plants, oil must be
change in viscosity of an oil for a given colorless, odorless and tasteless and if
temperature change. The rate of change comes in contact with the food should not
varies according to the type of base stock. discolor it.
Paraffin oils in general have a low rate of
viscosity change with change in d. Engine Operation. Normal operation of a
temperature; a particular paraffin oil was diesel engine subjects the lubricating oil to
arbitrarily assigned an index number of 100. high pressures and temperatures. The
Naphthenic oils have a high rate of viscosity results is oxidation and a tendency towards
change, and particular naphthenic oil was production of gums, resins, and acids. The
arbitrarily given an index number of zero. products of oil deterioration are an almost
The viscosity index, or VI, of any oil infinite series of compounds, differing
compares its rate of viscosity change with according to the oil used and the operating
temperature with these two standards. conditions. Furthermore, the oil may be
contaminated by metal particles, raw fuel oil,
b. Pour Point — is the lowest temperature at or the products of combustion. Soot, ash,
which oil will flow its own accord. It is not the partially burned fuel, or raw fuel may mix
only factor influencing the ease of starting a with the cylinder wall lubricant and
cold engine, especially after it is exposed for accelerate the deterioration of the lubricating
some time to cold weather. Special low- oil.
point lubricating oils may be used under
such circumstances, but the preferred Raw fuel oil will lower the flash and burning
method is to enclose suitably or protect the points of the lubricating oil, and lower the
engine by heating so that the lubricating oil viscosity. Filtering alone will not eliminate
and jacket water are at reasonable fuel oil; a distillation process is necessary.
temperatures before starting. The presence of fuel is detected by flash
point and change in viscosity.
c. Flash Point — In lubricating oils the flash
point is valuable for purposes of Oxidation or lubricating oil forms acidic
identification. The flash point of an oil is products. Periodic tests for neutralization
rough indication of its tendency to vaporize number will determine the rate of increase of
at high temperatures and therefore of oil acidity during service. Use the neutralization
consumption especially in internal number of the original or new oil as a basis
combustion engines. With used crankcase for comparison.
lubricants, the flash point gives an indication
of any dilution. Small engines are likely to have filters of
moderate capacity, and the lubricating oil is
Flash and fire points have the same thrown away periodically after a certain
meanings as for fuel oil, but the values are number of hours of use. Medium and large
much higher. Carbon residue has similar engines have more elaborate systems of
significance, but the test figure is a doubtful filtering the oil; the oil is clarified either by
indicator of the likelihood of engine deposits. the batch system or continuously. In the
Lubricating oils have flash points from 275- batch system, oil is drawn from the engine
700°F. periodically, clarified, and stored for future
use. No clarified oil is ever thrown away;
Color The color of oil is no indication of its
—
only residues or sludges are discarded.
lubricating qualities, except in so far as When the batch system is used, some
contamination may be evident. Sometimes operators have an analysis of the crankcase
the degree of deterioration can be estimated oil made periodically, and drain strictly
by comparing its color to that of unused oils. according to the indications shown. The
larger the establishment, the more essential
In same applications, color is quite that the correct grade of oil be used, that
important. In textile machines, oil may likely crankcase oil be kept in prime condition, and
cause stains in the textiles being that losses and wastes be reduced to a
manufactured. Stained textile might be minimum.
rejected and therefore light colored oils may
be preferred to dark color oils.
311
CHAPTER 15— FUELS AND LUBRICANTS
TYPICAL PROPERTIES OF LIQUEFIED PETROLEUM GAS
Section 12.0 Units of Heat Measurement
Property Method Guaranteed Typical
12.1 Several units for measuring the quantity of heat Specifications Tests
in a body are in use. The relations between Cu. Strip,
Corrosion,
them are given in Table 15.13.1 1 hr
@ 38°C ASTM D 1838 1 Max. 1
The British thermal unit (BTU) generally used in
Distillation, 95%
engineering work in the United States and Great Evaporated at 760
Britain is 1/180 of the heat required to raise the mm Hg. °F ASTM D 1837 32
temperature of 1 lb. of water from 32 to 212 F.
Originally, it was defined as the quantity of heat Specific Gravity @
60/60°F ASTM D 1657 Report 0.567
required to raise 1 lb. of water from 62 to 63 F,
but the former definition is now generally Sulfur, Grains/ 100
accepted. cu.ft ASTMD2784 l5Max. 2
Table 15.13.la
Relation of the Various Units of Heat
Btu Kg-cal Gram-cal Mean cal Ostwald cal Lb-cal
312
CHAPTER 15— FUELS AND LUBRICANTS
Table 15.13.lb
Mechanical Equivalent of Heat
Joules Watt-
Kg-
Ft-lb Btu G-cal hr, Hp-hr
roe-ter
mt. Abe mt.
1000 138.26 1355.4 1355.8 1.2849 323.79 0.3765 0.50505x
1 ft-lb
x i0 x io x i02 x i0 x io x i0 x io 106
Gum Existent
mg/i OOml ASTM D38i 4 maximum 2
Induction Period,
@ 100°C, Minutes ASTM D525 480 maximum 1440
Lead, Tetra Alkyl,
gm PB/litre
@15°C ASTM D2547 0.48 maximum 0.2985
313
CHAPTER 15— FUELS AND LUBRICANTS
Color, Say bolt ASTM D156 21 maximum + 30 Density, Kg/li. ASTM D1298 0 885 mm. — 0.9587
@ 15°C 0.990 max.
Corrosion, Copper
Strip, 3 hr@ 50°C ASTM D130 1 maximum 1 Flash Point
Pensky Martens,
Distillation, End Point, °CASTM D86 274 maximum 246 Closed Cup, °C ASTM D93 60 mm. 81
Water by distillation,
TYPICAL PROPERTIES OF PREMIUM GASOLINE ASTM D95 0 5 maximum 0.2
Doctor Test IP 30 Negative Negative Color ASTM ASTM D1500 3.0 maximum 1.0
Sulfur, mass % ASTM D1266 0.20 maximum 0.016 Density, Kg/litre ASTM D1298 0.815 mm. 0.8407
@ 15°C 0.875 max.
Vapor Lock Protection ASTM D439
Temperature Appendix Xl.3 Distillation, °C ASTM D86
(for V/L = 20), °C 57 mm. ei 90% Recovered 377 maximum 351
End Point 400 maximum 386
Vapor Pressure Reid,
Kpa @ 37.8°C ASTM D323 75 maximum 59 Flash Point,
Pensky Martens
—
Viscosity, Kinematic
cST @40°C ASTM D445 1.71 mm — 2.8
5.5 max.
Water and Sediment by
Centrifuge, Vol. % ASTM D 1796 0.10 maximum Trace
314
CHAPTER 15— FUELS AND LUBRICANTS
315
CHAPTER 16- MATERIALS
Chapter 16
MATERIALS
316
CHAPTER 16- MATERIALS
tungsten base high speed the general purpose high speed tool
steels, the tool steels listed in steels, combining the economic
this category are considered advantages of the molybdenum type
to have molybdenum as the steels with greater ease of hardening,
principal alloying constituents, excellent wear resistance and
this element being also used improved toughness. It is preferred
in the designation of the steel type for the manufacture of
group. Actually, in several general purpose lathe tool; like milling
types listed in this category cutters, taps, dies, reamers and also
other significant elements like for form tools in lathe operations.
tungsten and cobalt might be
present in equal, or even 16.1.2.3 AISI M3: A high speed tool steel with
greater amount. The increased vanadium content for
available range of types improved wear resistance, yet still
comprises also high speed below the level where vanadium
tool steels with higher than would interfere with the ease of
usual carbon and vanadium grinding. Preferred for cutting tools
content; these alloying requiring the improved wear
elements have been resistance, like broaches, form tools,
increased to obtain better milling cutters, chasers, reamers, etc.
abrasion resistance although
such a change in composition 16.1.2.4 AISI M7: The chemical composition
may adversely affect the of this type similar to that of Ml except
machine-ability and the grind- for the higher carbon and vanadium
ability of the steel. The series content which raises the cutting
in whose AISI identification efficiency without materially reducing
numbers 4 is the first digit the toughness. Because of its
where developed for attaining sensitivity to decarburization heat
exceptionally high hardness in treatment in a salt bath or a controlled
heat treatment which, for atmosphere is advisable. Used for
types, usually comprises triple blanking and trimming dies, shear
tempering rather than the blades, lathe tools and thread rolling
double tempering generally dies.
applied for high speed tool
steels. 16.1.2.5 AISI M1O: While the relatively high
vanadium content assures excellent
16.12 Properties and Applications of Frequently wear and cutting properties, the only
Used Molybdenum Types slightly increased carbon does not
cause brittleness to an extent which is
16.12.1 AISI M: This was developed as a harmful in many applications. Form
substitute for the classical T to save cutters and single point lathe tools,
on the alloying element tungsten by broaches, planer tools, punches,
replacing most of it with molybdenum. blanking dies, shear blades, etc., are
In most uses this steel is an examples of typical uses.
acceptable substitute, although it
requires greater care or more 16.1.2.6 AISI M42: In applications where high
advanced equipment for its heat hardness both at regular and at
treatment than the tungsten alloyed elevated temperatures is needed, this
type it replaces. Selected for cutting type of high speed steel with high
tools like drills, taps, milling cutters, cobalt content can provide excellent
reamers, lathe tools used for lighter service. Typical applications are tools
cuts, and also for shearing dies. bits, form tools, shaving tools, fly
cutters, roll turning tools, thread rolling
dies, etc. Important uses are found
16.1.2.2 AISI M: Similar to M yet with for M42, and also for other types of
substantial tungsten content replacing the “M40” group in the working of
a part of the molybdenum. It is one of “difficult-to-machine” type alloys.
317
CHAPTER 16- MATERIALS
318
CHAPTER 16— MATERIALS
16.1.4.2 Cold Work Tool Steels — High results in excellent resistance to wear
Carbon, High Chromium Types. The and abrasion and also provides
chemical composition of tool steels of superior compressive strength as long
this family is characterized by the very as the pressure is gradually applied
high chromium content, in the order of without exerting sudden shocks. In
12 to 13 per cent, and the hardening, an oil quench is used,
uncommonly high carbon content in without affecting the excellent non
the range of about 1.50 to 2.30 per deforming properties of this type. Its
cent. Additional alloying elements deep hardening made it particularly
which are present in different amounts suitable for tools which require
in some of the steel types of this repeated re-grinding during their
group are vanadium, molybdenum service life, such as different types of
and cobalt, each of which contributes dies and punches. The more
desirable properties. The important applications comprise
predominant properties of the whole blanking, stamping and trimming dies
group are: (a) excellent dimensional and punches for long production runs;
stability in heat treatment where with forming, bending and drawing tools;
one exception, air quench is used; (b) also structural elements like plug and
great wear resistance particularly in ring gages, lathe centers, etc., in the
the types with the highest carbon applications where high wear
content, and (c) rather good resistance is important.
machinability.
16.1.5.3 Cold Work Tool Steels — Oil
16.1.5 Properties and Applications of Frequently Hardening Types. With a relatively
Used High Carbon High Chromium Types
—
low percentage of alloying elements,
yet with a substantial amount of
16.1.5.1 AISI D2: An air hardening die steel manganese, these less expensive
with high carbon, high chromium types of tool steels attain good depth
content with several desirable tool of hardness in an oil quench, although
steel properties, such as abrasion at the cost of reduced resistance to
resistance, high hardness as well as deformation. Their good machinability
non-deform ing characteristics. The supports general purpose application,
carbon content of this type, although yet because of relatively low wear
relatively high, is not particularly resistance they are mostly selected for
detrimental to its machining. The comparatively short-run work.
ease of working can further be
improved by selecting the same basic 16.1.6 Properties and Applications of Frequently-
type with the addition of sulfur. Used Oil Hardening Types
Several steel producers supply the
sulfurized version of D2, in which the 16.1.6.1 AISI 01: A low alloy tool steel which
uniformly distributed sulfide particles is hardened in oil and exhibits only a
substantially improve the machinability low tendency to shrinking or harping.
and the resulting surface finish. The It is used for cutting tools, the
application comprise primarily cold operation of which does not generate
working press tools for shearing high heat, such as taps and threading
(blanking and stamping dies, dies, reamers, broaches, and for
punches, shear blades) for forming press tools like blanking, trimming,
(bending, seaming), also for the and forming dies in short or medium-
thread rolling dies, solid gages, and run operations.
wear resistant structural parts. Dies
for hot trimming of forging are also
made of D2 when heat treated to a 16.1.6.2 AISI 02: Manganese is the dominant
lower hardness for the purpose of alloying element in this type of oil
increasing toughness. hardening tool steel which has good
non-deforming properties, can be
16.1.5.2 AISI D3: The high carbon content of machined easily and performs
this high chromium tool steel type satisfactorily in low volume production.
319
CHAPTER 16- MATERIALS
320
CHAPTER 16- MATERIALS
16.1.7.4 AISI H19: This high-alloyed hot work sensitive to shock loads. Taking
tool steel, containing chromium, these properties into account, the
tungsten, cobalt and vanadium, has principal applications include
excellent resistance to abrasion and extrusion dies for brass in long run
shocks at elevated temperature. It is operation, hot forming and gripper
particularly well adapted to severe hot dies with shallow impressions,
work uses where the tool, in order to punches which are subjected to great
retain its size and shape, must wear yet only to moderate shocks, hot
withstand wear and the washing out shear blades, etc.
effect of hot work material. Typical
applications include brass extrusion 16.1.8.3 AlSI H26: This high alloyed tungsten
dies and dummy blocks, inserts for type hot work steel resembles in its
forging and valve extrusion dies, press composition the type high speed steel
forging dies, hot punches, etc. AISI Ti, except for the somewhat
lower carton content for improved
16.1.7.5 Hot Work Tool Steels — Tungsten toughness. The high amount of
Types. Substantial amount of tungsten provides the maximum
tungsten, yet very low carbon content resistance to the softening effect of
characterizes the hot work tool steel of elevated temperature and assures
this group. These tool steels have excellent wear-resistant properties,
been developed for applications including the withstanding of the
where the tool is in contact with the washing-out effect of certain
hot work material over extended processes. However, this type is less
periods of time, therefore the resistant to thermal shocks than the
resistance of the steel to the softening chromium hot work steels. Typical
effect of elevated temperatures is of applications comprises extrusion dies
prime importance, even to the extent for long production runs, extrusion
of accepting a lower degree of mandrels operated without cooling,
toughness. hot piercing punches, hot forging dies
and inserts. It is used as special
16.1.8 Properties and Applications of Frequently- structural steel for springs operating at
Used Tungsten Types. elevated temperatures. The areas of
use also include structural parts, like
16.1.8.1 AISI H21: This is a medium tungsten clutch members, pawls, knuckle pins,
alloyed hot work tool steel with etc., which must withstand shock
substantially increased abrasion loads and still display good wear
resistance over the chromium alloyed properties.
types, yet possessing a degree of
toughness which represents a 16.1.8.4 AISI F2: This carbon-tungsten type is
transition between the chromium and one of the most abrasion resistant of
the higher alloyed tungsten steel all water hardening tool steels.
types. The principal application are However, it is sensitive to thermal
for tools subjected to continued changes, such as are involved in heat
abrasion, yet to only a limited amount treatment and is also susceptible to
of shock loads, like tools for the distortions. Consequently, its use is
extrusion of brass, both dies and limited to tools of simple shape in
dummy blocks, pierces for forging order to avoid cracking in hardening.
machines, insert for forging tools, hot The shallow hardening characteristics
nut tools, etc. Another typical of F2, which result in a tough core, are
application is dies for the hot extrusion desirable properties for certain tool
of automobile valves. types which, at the same time, require
the excellent wear-resistant properties
16.1.8.2 AISI H24: The comparatively high of this tool steel type.
tungsten content (about 14 per cent)
results in good hardness, great 16.1.9 Water Hardening Tool Steels Steel types
—
compression strength and excellent in this category are made without, or with only
abrasion resistance, but makes it a minimum amount of alloying elements and
321
CHAPTER 16— MATERIALS
need in their heat treatment the harsh 16.1.10 Recommended Applications of Water
quenching action of water or brine, hence the Hardening Type W-l (Plain Carbon) Tool
general designation of the category. Water Steels
hardening steels are usually available with
different percentages of carbon, to provide 16.1.10.1.1 Group I (C-0.70 to 0.90%):
properties required for different applications; Relatively tough and therefore
the classification system lists a carbon range preferred for tools which are
of 0.60 to 2.40 per cent. In practice, however, subjected to shocks or abusive
the steel mills produce these steels in a few treatment. For such
varieties of differing carbon content, often applications as: hand tools —
between these grades, which are not offered dies, shear knives, cutting and
forming dies; and fixture
by all steel mills, are defined in principle only.
The distinguishing characteristics are purity elements — drill bushing, lathe
and consistency, resulting from different centers, collets, fixed gages.
degrees of process refinement and
inspections steps applied in making the steel. 16.1.10.1.3 Group Ill (C-1.05 to 1.20%):
Higher qualities are selected for assuring The higher carbon content
dependable uniformity and performance of the increases the depth of hardness
tools made of the steel. penetrations, yet reduces
toughness, thus the resistance
Since the groups with higher carbon content to shock loads. Preferred for
are more sensitive to heat treatment defects applications where wear
and are generally used for the more resistance and cutting ability are
demanding applications, the better grades are the prime considerations. For
usually chosen for the high carbon types and such applications as: hand
the lower grades for applications where steels tools — woodworking chisels;
with lower carbon content only are needed. paper knives; cutting tools (for
low speed applications) milling
—
However, this last mentioned property may cutters, reamers; planer tools,
prove a desirable characteristic in certain thread chaser center drills; and
applications, such as e.g., cold heading dies die parts — cold blanking,
because the relatively shallow hard case is coining, bending dies.
supported by tough, although softer core.
The AISI designation for water hardening tool 16.1.10.1.4 Group IV (C-1.20 to 1.30%):
steels is W, followed by a numeral indicating The high carbon content
the type, primarily defined by the steel’s produces a hard case of
considerable depth, with
chemical composition, as shown in the
following table. improved wear resistance, yet
sensitive to shock and
concentrated stresses.
Selected for applications where
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CHAPTER 16 — MATERIALS
the capacity to withstand electrode method involving a re
abrasive wear is needed, and melting of the steel originally
also where the retention of a produced by conventional processes.
keep edge or the original shape Inside a vacuum-tight shell which has
of the tool is important. For been evacuated, the electrode cast of
such applications as: cutting tool steel of the desired chemical
tools (a) for finishing work, like
—
analysis is lowered into a water cooled
cutters, reamers, (b) for cutting copper mold where it strikes a low
chilled cast iron and forming voltage-high amperage are causing
tools — for ferrous and non the electrode to be consumed by
ferrous metals, burnishing tools. gradual melting. The undesirable
By adding small amounts of gases and volatile are drawn off by
alloying elements to W-steel the vacuum, and the inclusions float
types 2 and 5, certain on the surface of the pool
characteristics which are accumulating on the top of the
desirable for specific produced ingot, to be removed later
applications, are improved. The by cropping. In the field of tool steels
vanadium in type 2 contributes the consumable electrode vacuum
to retaining a greater degree of melting (CVM) process is applied
fine grain structure after heat primarily to the production of special
treating. Chromium in type 5 grades of hot work and high speed
improves the deep hardening tool steels.
characteristics of the steel, a
property being needed for large 16.1.11.2 High Speed Tool Steel produced by
sections, and also assists in Powder Metallurgy: The steel
maintaining a keen cutting produced by conventional methods is
edge, which is desirable in reduced to a fine powder by a gas
cutting tools, like broaches, atomization process. The powder is
reamers, threading taps and compacted by a hot isostatic method
dies. (a) Tool bits: these are with pressures in the range of 103
semi-finished tools and used by N/mm to 117 N/mm. The compacted
clamping in a tool holder or billets are hot rolled to the final bar
shank in a manner permitting size, yielding a tool-steel material
ready replacement. Tool bits are which has 100 per cent theoretical
commonly made o high speed density. High speed tool steels
types of tool steels, mostly in produced by the P/M method offer a
square, but also in round, tool material providing increased tool
rectangular and other shapes. wear life and high impact strength, or
Tool bits are made of hot rolled particular advantage in the interrupted
bars and ground form, ready for cuts.
us after the appropriate cutting
edges are ground, usually in the Section 16.2 Standards Steels
user’s plant.
16.2.1 Composition and Specifications
16.1.11 Advances in Tool Steel-Making
Technology. In recent years significant 16.2.1.1 The standard steel compositions of the
advances in processes for tool steel
Society of Automotive Engineers
production have been made which offer
(SAE), Inc., given in the
more homogeneous materials •of greater
accompanying table, are considered
density and higher purity for applications
adequate for practically all parts made
where such extremely high quality is
of ferrous materials that are necessary
required. Two of these newer methods of
for the production of automotive
tool steel production are of particular
apparatus, and include grades that
interest.
have been found commercially
available and technically adequate for
16.1.11.1 Vacuum Melted Tool Steels: These
the service required of such parts.
are produced by the consumable Definite applications of SAE steels are
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CHAPTER 16- MATERIALS
not specified as the selection of a 16.2.1.4 High Strength, Low Alloy Steel,
proper steel for a given part must SAE 950. High strength, low alloy
depend upon an intimate knowledge steel represents a specific type of
of a number of important factors, such steel in which enhanced mechanical
as the availability and price of properties and, in most cases, good
materials, the detailed design of the resistance to atmospheric corrosion
part, and the severity of the service to are obtained by the addition of
be imposed, whether the part is to be moderate amounts of one or more
forged or machined and its alloying elements other than carbon.
machinability; hence only general
applications are indicated. (See Steels of this type are normally
following tables). furnished in the hot rolled or annealed
condition to minimum mechanical
16.2.1.2 Specifications Number for Steels. properties. They are not intended for
A numeral index system is used for quenching and tempering. The user
SAE steel specification, which makes should not subject them to such
it possible to use specification treatment without assuming
numerals on shop drawings and responsibility for the ensuing
blueprints that are descriptive of the mechanical properties. Where these
kind of material covered by such steels are used for fabrication by
numbers. The first figure indicates the welding, no preheat or post heat is
class to which the steel belongs: thus required. In certain complex
“1” indicates a carbon steel, “2” a structures, stress relieving may be
nickel steel, etc. In the case of the desirable. These steels may be
alloy steel, the second figure generally obtained in the standard shape or
indicates the approximate percentage forms normally available in carbon
of the predominant alloying element. steel.
Usually the last two or three figures
indicate the average carbon content in 16.2.2 Application. These steels, because of their
“points”, or hundredths of 1 per cent. enhanced strength, corrosion and erosion
Thus “2340” indicates a nickel steel of resistance, and their high strength-to-weight
approximately 3 per cent nickel (3.25 ratio and service life, are adapted particularly
to 3.75), and 0.40 per cent carbon for use in mobile equipment and other
(0.38 to 0.43). In some instances, in structures where substantial weight savings
order to avoid confusion, it has been are generally desirable. Typical application
found necessary to depart from this are automotive bumper face bars, truck
system of identifying the approximate bodies, frames and structural members,
alloy composition of a steel by varying scrapers, dump wagons, cranes, shovels,
the second ad third digits of the booms, chutes, conveyors, railroad and
number. An instance of such industrial cars.
departure is the steel numbers
selected for several of the corrosion 16.2.2.1 Carbon Steels.
and heat-resisting alloys.
(a) SAE Steels 1006, 1008, 1010, 1015:
16.2.1.3 Quality Variations of Carbons and These steels are the lowest carbon
Alloy Steels. Carbon steels may be steels of the plain carbon type, and
produced with chemical composition are selected where cold formability
(carbon, manganese, phosphorous, is the primary requisite of the user.
sulfur, and silicon) within the specified They are produced both as rimmed
limits of a given grade and still have and killed steels. Rimmed steel is
characteristics that are dissimilar. used for sheet, strip, rod, and wire
Each grade and quality variations where excellent surface finish or
thereof has a proper and useful place, good drawing qualities are required,
depending upon the end products to such as body and fender stock,
be made and the methods of hoods, lamps, oil pans, and other
fabrication. deep drawn and formed products. It
is also used for cold heading wire
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CHAPTER 16— MATERIALS
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CHAPTER 16- MATERIALS
(c) SAE 1030, 1033, 1034, 1035, 1036, a higher strength level and more
1038, 1039, 1040, 1041, 1042, uniformity is essential, such as
1043, 1045, 1046, 1049, 1050, some front suspension parts.
1052: These steels, of the medium Forging such as connecting rods,
carbon type, are selected for uses steering arms, truck front axles,
where higher mechanical properties axles shafts, and tractor wheels are
are needed and are frequently commonly made from the SAE 1038
further hardened and strengthened to 1045 group. Larger forging at
by heat-treatment or by cold work. similar strength levels need more
These grades are ordinarily carbon and perhaps more
produced as killed steels. manganese. Examples are
crankshafts from SAE 1046 and
Steels in this group are suitable for 1052. These steels are also used
a wide variety of automotive type for small forging where high
applications. The particular carbon hardness after oil quenching is
and manganese level selected is desired. Suitable heat treatment is
affected by a number of factors. necessary on forging from this
Increase in the mechanical group to provide machinability.
properties required in section These steels are also widely used
thickness, or in depth of hardening, for parts machined from bar stock,
ordinarily indicates either higher the selection following an identical
carbon or manganese or both. The pattern to that described for forging.
heat treating practice preferred, They are used both with and without
particularly the quenching medium, heat treatment, depending on the
has a great effect on the steel application and the level of
selected. In general, any of the properties needed. As a class they
grades over 0.30 carbon may be are considered good for normal
selectively hardened by induction or machining operations. It is also
flamed methods. possible to weld these steels by
most commercial methods, but
The lower carbon and manganese precautions should be taken to
steels in this group find usage for avoid cracking from too rapid
certain type of cold formed parts. cooling.
SAE 1030 is used for shift and
brake levers, SAE 1034 and 1035 (d) SAE 1055, 1060, 1062, 1064, 1065,
are used in the form of wire and rod 1066, 1070, 1074, 1078, 1080,
for cold upsetting such as bolts and 1085, 1086, 1090, 1095: Steel in
stud. In practically all cases the this group are of high carbon type,
parts cold formed from these steels having more carbon than is required
are heat treated prior to use. to achieve maximum as quenched
Stamping is usually limited to flat hardness. They are used for
parts or simple bends. The higher applications where the higher
carbon SAE 1038, 1040 and 1042 carbon is needed to improve wear
are frequently cold drawn to characteristics for cutting edges, to
specified physical properties for use make springs, and for special
without heat treatment fro some purposes. Selection of a particular
applications, such as cylinder head grade is affected by the nature of
studs. All of this group of steels for the part, its end use, and the
forging, the selection being manufacturing methods available.
governed by the section size and
the physical properties desired after In general, cold forming methods
heat treatment. Thus SAE 1,030 are not practical on this group of
and 1,035 are used for shifter forks steels, being limited to flat stamping
and many small forging where and springs coiled from small
moderate properties are desired, diameter wire. Practically all parts
but the deeper hardening SAE 1036 from these steels are heat treated
is used for more critical parts where before use, with some variations in
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CHAPTER 16- MATERIALS
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CHAPTER 16— MATERIALS
328
CHAPTER 16— MATERIALS
The most desirable hardness for the content for any given application than
core depends upon the design and would be specified for other alloy
functioning of the individual part. In steels, due to the alloy content of
general, where high compressive these steels. For example, as SAE
loads are encountered relatively 4063 is used for the same
high core hardness is beneficial in applications as SAE 4140, 4145 and
supporting the case. Low core 5150. Consequently in the following
hardness may be desirable where discussion, the carbon molybdenum
great toughness is essential. steels have been shown in the groups
where they belong on the basis of
The case hardening steels may applications rather than carbon
be divided into three general content.
classes depending upon
hardenability of the core. For the present discussion, steels of
each carbon content are divided into
(1) Low Hardenability Core. two or three groups on the basis of
SAE 4017, 4023, 4024, 4027, hardenability. Transformation ranges
4082, 4608, 4615, 4617 8615, and consequently heat treating
8617 practices vary somewhat with different
alloying elements even though the
(2) Medium Hardenability Core. hardenability is not changed.
SAE 1320, 2317, 2512, 2515,
3115, 3120, 4032, 4119, (a) .30 .47 Mean Carbon Content of
-
Mean Carbon Content of SAE (b) .40 .42 Mean Carbon Content
-
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CHAPTER 16- MATERIALS
(2) Medium Hardenability: SAE (a) SAE 30301: This steel is capable
2345, 3145, 3150, 4145, of attaining high tensile strength
5147, 5150, 8645, 8647, and ductility by moderate or
8650, 8745, 8747, 8750, severe cold working. It is used
9445, 9845 largely in the cold working. It is
used largely in the cold rolled or
(3) High Hardenability: SAE cold drawn condition in the form of
4150, 9850 sheet, strip and wire. Its corrosion
resistance is good but not equal to
SAE 30302.
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CHAPTER 16- MATERIALS
(g) SAE 30316: This steel is (c) SAE 51416F: This is a free
recommended for use in parts machining grade for the
where unusual resistance to manufacture of parts produced in
chemical or salt water corrosion is automatic screw machines.
necessary. It has superior creep
strength at elevated temperatures. (d) SAE 51420: This steel is capable
of heat treating to a relatively high
(h) SAE 30317: This steel is similar hardness. It will harden to a
to SAE 30316 but has the highest maximum of approximately 500
corrosion resistance of all these Brinell. It has its maximum
alloys in many environments. corrosion resisting qualities only in
the fully hardened condition. It is
(i) SAE 30321: This steel is used for cutlery, hardened pump
recommended for use in the shafts, etc.
manufacture of welded structures
where heat treatment after (e) SAE 51420F: This is similar to
welding is not feasible. It is also SAE 51420 except for its free
recommended for use where machining properties.
temperatures up to 871°C are
encountered in service. (f) SAE 51430: This is a steel of a
high chromium type not capable
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CHAPTER 16- MATERIALS
332
CHAPTER 16— MATERIALS
about 18 per cent chromium and 8 per Section 16.4 Heat Treatment of Steel
cent nickel.
164.1 Effect of Rapid Cooling or Quenching
16.3.12 Stainless Steel with Free Machining Carbon Steel. Observations have shown that
Qualities. The high-chromium as the rate at which carbon steel is cooled
stainless steel alloys first produced from an austenitic state is increased, the
were extremely difficult to machine, temperature at which the austenite begins to
and grinding and polishing operations change into pearlite drops more and more
were also difficult and expensive. By below the slow cooling transformation
producing this steel with a high sulfur temperature of about 705°C. (For example, a
content or by the addition of selenium, 0.80 per cent carbon steel that is cooled at
free machining qualities can be such a rate that the temperature drops 260°C
obtained. Such stainless steels in one second will show transformation of
contain approximately 0.10 per cent austenite beginning at 500°C). As the cooling
carbon, 18 per cent chromium, 8 per rate is increased, the laminations of the
cent nickel, and 0.30 per cent sulfur pearlite formed by the transformation of the
(or 0.25 per cent selenium instead of austenite become liner and finer up to the
sulfur). They can be machined in point where they cannot be detected under a
automatic screw machines, with high power microscope, while the steel itself
regular tools at speed equal to or increases in hardness and tensile strength. As
closely approximating those used for the rate of cooling is still further increased, this
ordinary Bessemer screw stock. transformation temperature suddenly drops
These materials can also be easily down to around 260°C or lower, depending
drilled, tapped, and threaded with upon the carbon content of the steel. The
dies. Wire and tubing can be cold- cooling rate at which this sudden drop in
drawn by simply using the lime coat transformation temperature takes place is
and lubricants regularly employed for called the critical cooling rate. When a piece
drawing ordinary steel. of carbon steel is quenched at this rate or
faster, a new structure is formed. The
16.3.1.3 Characteristics of 18-8 Stainless austenite is transformed into martensite which
Steel. The chrome-nickel stainless is characterized by an angular needle-like
steel known as 18-8 is made to have structure and a very high hardness.
a tensile strength of from 620.68
2 to 689.65 N/mm
N/mm 2 in the If carbon steel is subject to a severe quench
annealed state. The elongation varies or to extremely rapid cooling, a small
from 60 to 70 per cent. Cold-working percentage of the austenite, instead of being
will increase the tensile strength from transformed into martensite during the
827.58 N/mm
2 to 862.06 N/mm .
2 quenching operation, may be retained.
Because of the high feeding pressure
required for drilling 18-8 stainless Over a period of time, however, this remaining
steels, a specially heat-treated high- austenite tends to be gradually transformed
speed drill with a heavy web section into martensite even though the steel is not
has been introduced. The web should subjected to further heating or cooling. Since
be thinned at the point and sulfur- martensite has a lower density than austenite,
base oil used as cutting fluid. such a change or “ageing” as it is called, often
results in an appreciable increase in volume or
16.3.1.4 General Properties of Alloy Steels.
“growth” and the setting up of new internal
Alloy or ‘special” steels are stresses in the steel.
combinations of iron and carbon with
some other element, such as nickel, 16.4.1.1 Steel Heat-Treating Furnaces.
chromium, tungsten, vanadium, Various types of furnaces heated by
manganese and molybdenum. All of
gas, oil or electricity, are used for the
these metals give certain distinct
heat-treatment of steel. These include
properties to the steel, but in all cases the oven or box type in various
the principal quality is the increase in
modifications for “in-and-out” or for
hardness and toughness.
continuous loading and unloading; the
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CHAPTER 16- MATERIALS
retort type; the pit type; the pot type; if large enough, or in a container
and the salt-bath electrode type. of some sort. The use of a retort
permits special gas atmospheres
(a) Oven or Box Furnace: This type to be employed for carburizing,
of furnace has a box or oven- nitriding, etc.
shaped heating chamber. The
“in-and-out” oven furnaces are (c) Pit Type Furnace: This is a
loaded by hand or by a track vertical furnace arranged for the
mounted car which, when rolled loading of parts in a metal basket.
into the furnace, forms the bottom The parts are heated by
of the heating chamber. The car convection, the basket, when
type is used where heavy or bulky lowered into place, hitting into the
pieces must be handled. Some furnace chamber in such a way as
oven type furnaces are provided to provide a dead-air-space to
with a full muffle or a semi-muffle prevent direct heating.
which is an enclosed refractory
chamber into which the parts to (d) Pot Type Furnace: This furnace
be heated are placed. The full- is used for the immersion method
muffle, being fully enclosed, of heat-treating small parts. A
prevents any flames or burning cast-alloy pot is employed to hold
gases from coming in contact with a bat of molten lead or salt in
the work and permits a special which the parts are placed for
atmosphere to be used to protect heating.
or condition the work. The semi-
muffle which is open at the top, (e) Salt Bath Electrode Furnace: In
protects the work from direct this type of electric furnace,
of the flame heating is accomplished by
impingement
although it does not shut the work means of electrodes suspended
off from the hot gases. In the directly in the salt bath. The
patented grouping and design of
direct-heat type oven furnace, the
electrodes provide an
work is open to the flame. In the
electric oven furnace a retort is electromagnetic action which
provided if gas atmospheres are results in automatic stirring action
to be employed to confine the gas through the bath. This tends to
and prevent it from attacking the produce an even temperature
heating elements. throughout.
Where muffles are used, they must be 16.4.1.2 Basic Steps in Hardening.
replaced periodically and a greater amount of The operation of hardening steel
fuel is required than in a direct-heat type of consists fundamentally of two steps.
oven furnace. The first step is to heat the steel to
some temperature usually at least
For continuous loading and unloading, there 38°C above its transformation point so
are several types such as rotary hearth car; that it becomes entirely austenitic in
roller-furnace belt, walking-beam or pusher- structure. The second step is to
conveyor; and a continuous-kiln type through quench the steel at some rate faster
which track-mounted cars are run. In the than the critical rate (which depends
continuous type of furnace, the work may pass on the carbon content, the mounts of
through several zones maintained at different alloying elements present other than
temperatures for preheating, heating, soaking, carbon, and the grain size of the
and cooling. austenite) to produce a martensitic
structure. The hardness of a
(b) Reactor Furnaces: This is a martensitic steel depends upon its
vertical type of furnace provided carbon content and ranges from about
with a cylindrical metal retort into 460 Brinell at 0.20 per cent carbon to
which the parts to be heat-treated about 710 Brinell, pearlite about 240
are suspended either individually,
334
CHAPTER 16— MATERIALS
Brinell, and cementite around 550 max. 150; iron, max. 2; lead, max.
Brinell. 0.40 per cent.
335
CHAPTER 16- MATERIALS
Composition of No. 62: Copper, 86 to 16.5.1.11 Bronze Backing for Lined Bearing.
89; tin, 9 to 11; lead, max. 0.20; iron, SAE Standard No. 66. This is an
max. 0.06; zinc, I to 3 per cent. expensive but suitable alloy for
bronze-backed bearings of connecting
Physical Properties: Tensile strength, rods or main engine bearings.
; yield point, 83 N/mm
207 N/mm
2 ;
2
elongation in 50 mm (or proportionate Composition: Copper, 83 to 86; tin,
gage length), 10 per cent. 4.50 to 6; lead, 8 to 10; zinc, max. 2;
other impurities, max. 0.25 per cent.
16.5.1.8 Leaded Gun Metal Castings. SAE
Standard No. 63. This general-utility 16.5.1.12 Bronze Bearing Castings. SAE
bronze combines strength with fair Standard No. 660. This composition
machining qualities, It is especially is widely used for bronze bearings.
good for bushings subjected to heavy Typical applications in the automotive
loads and severe working conditions. industry include such parts as spring
It is also used for fittings subjected to bushing, steering-knuckle bushings,
moderately high water or oil piston-pin bushings, thrust washers,
pressures. etc.
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CHAPTER 16— MATERIALS
337
CHAPTER 16— MATERIALS
16.5.2.8 Phosphor Bronze Sheet and Strip. Composition of No. BOB: Copper,
SAE Standard No. 77. Typical uses 63.0 to 68.5; lead, max. 0.10; iron,
for this sheet and strip include springs, max. 0.05; zinc, remainder.
switch parts, sleeve bushings, clutch
discs, diaphragms, fuse clips, and 16.5.2.11 Phosphor Bronze Wire and Rod.
fastener. There are two grades of this SAE Standard No. 81. This alloy is
alloy, 77A and 77C. Six tempers are used for springs, width parts, fastener,
applied to this alloy, namely, soft, half and cotter pins. It should withstand
hard, hard, extra hard, spring and being bent cold through an angle of
extra spring. 120 degrees without fracture, around
a pin with a diameter twice the
Composition of No. 77A: Tin, 3.5 to diameter of the wire.
5.8; phosphorus, 0.03 to 0.35; lead,
max. 0.05; iron, max. 0.10; zinc, max. Composition of No. 81: Tin, 3.50 to
0.30; antimony, max. 0.01; copper, tin 5.80; phosphorus, 0.03 to 0.35; lead,
and phosphorus, mm. 99.50. max. 2.05; iron, max. 0.10; zinc, max.
0.30; copper, tin and phosphorus,
Composition of 77C; Tin, 7.0 to 9.0; mm. 99.50.
phosphorus, 0.03 to 0.35; lead, max.
0.05; iron, max. 0.10; zinc, max. 0.20; Mechanical Properties: Minimum
antimony, max. 0.01; copper, tin, and tensile strengths of hard drawn wire in
phosphorus, mm. 99.50. coils range from 1000 N/mm2 to 724
2 as the wire diameter range
N/mm
16.5.2.9 Red Brass and Low Bras Sheet and from 0.64 mm to 13 mm. Minimum
Strip. SAE Standard No. 79. There tensile strengths of spring temper rods
are two grades designated as 79A 2 to 620 N/mm
range from 862 N/mm 2
(Red Brass, 85 per cent) and 79B
338
CHAPTER 16- MATERIALS
339
CHAPTER 16 - MATERIALS
Aluminum has non-sparking and non- to produce the various tempers. The
magnetic characteristics which make temper designation follows the alloy
the metal useful for electrical shielding designation, being separated by a
purposes such as in bus bar housing dash.
or enclosures for other electrical
equipment and for use around Basic temper designations consist of
inflammable or explosive substances. letters. Subdivisions of the basic
tempers, where required, are
Aluminum can be cast by any method indicated by one or more digits
known to foundrymen. It can be rolled following the letter. These designate
to any desired thickness down to foil specific sequences of basic treatment,
thinner than paper and in sheet form but only operations recognized as
can be stamped, drawn, spun or roll- significantly influencing the
formed. The metal also may be characteristics of the product are
hammered or forged. Aluminum wire, indicated. Should some other
drawn from rolled rod, may be variation of the same sequence of
stranded into cable of any desired basic operations be applied to the
size and type. The metal may be same alloy, resulting in different
extruded into a variety of shapes. characteristics, then additional digits
are added.
It may be turned, milled, bored, or
machined in machines often operating (a) The basic temper designations
at their maximum speeds. Aluminum and subdivisions are as follows:
rod and bar may readiiy be employed
in the high-speed manufacture of -- F as Fabricated: Applies to
automatic screw-machine parts. products which acquire some
temper from Aluminum alloys are
Almost any method of joining is light in weight compared to steel,
applicable to aluminum —riveting, brass, nickel or copper; can be
welding or brazing. A wide variety of fabricated by all common range of
mechanical aluminum fasteners sizes, shapes and forms; resist
simplifies the assembly of many corrosion, readily accept a wide
products. Resin bonding of aluminum range of surface finished, have
parts has been successfully good electrical and thermal
employed, particularly in aircraft conductivities; and are highly
components. reflective to both heat and light
340
CHAPTER 16- MATERIALS
341
CHAPTER 16 — MATERIALS
342
CHAPTER 16— MATERIALS
343
CHAPTER 16— MATERIALS
344
CHAPTER 16— MATERIALS
rate that the temperature drops 26000 (1) Oven or Box Furnace:
in one second will show This type of furnace has a
transformation of austenite beginning box or oven-shaped
at 500°C). As the cooling rate is heating chamber. The “in-
increased, the laminations of the and-out” oven furnaces
pearlite formed by the transformation are loaded by hand or by
of the austenite become finer and a track mounted car by
finer up to the point where they cannot hand or b y a track
be detected under a high power mounted car which, when
microscope, while the steel itself rolled into the furnace,
increases in hardness and tensile forms the bottom of the,
strength. As the rate of cooling is still heating chamber, The car
further increased, this transformation type is used where heavy
temperature suddenly drops down to or bulky pieces must be
around 26000 or lower, depending handled. Some oven type
upon the carbon content of the steel. furnaces are provided
The cooling rate at which this with a full muffle or a
temperature takes place is called the semi-muffle which is an
critical cooling rate. When a piece of enclosed refracable as
carbon steel is quenched at this rate plate in the as rolled
or faster, a new structure is formed. condition designated as J
The austenite is transformed into ir. Dowmetal J-1 has the
martensite which is characterized by best mechanical
an angular needle-like structure and a properties of the rolled
very high hardness. alloys and is used in
applications where
If carbon steel is subject to a severe strength is most
quench or to extremely rapid cooling, important. Where better
a small percentage of the austenite, formability is desired
instead of being transformed into along with good shear
martensite during the quenching and tensile strengths,
operation, may be retained. Dowmetal FS-1 Is used.
Dowmetal M is used
Over a period of time, however, this where maximum
remaining austenite tends to be weldability and formability,
gradually transformed into martensite low cost, and moderate
even through the steel is not strength are desired.
subjected to further heating or cooling.
Since marten-site has a lower density (2) Forging Alloys: The
than austenite, such a change or ultimate tensile strengths
“ageing” as it is called, often results in range from 248 N/mm to
an appreciable increase in Volume or 345 N/mm
2 and the yield
‘growth” and the setting up of new strengths from 158.6
internal stresses in the steel. 2 to 234.5 N/mm
N/mm .
2
(a) Steel Heat-Treating Furnace (3) Extruded Alloys: For
Various types of furnaces heated bars and rods the ultimate
by gas, oil or electricity, are used tensile strengths range
for the heat-treatment of steel. from 262 to 345 N/mm
2
These include the oven or box and the yield strengths
type in various modifications for from 179.3 N/mm2 to
“in-and-out” or for continuous 234.5 N/mm
.
2
loading and unloading; the retort
type; The pit type; the pot type; (b) Heat-Treatment of Dowmetal
and the salt-bath electrode type. Alloys. Dowmetal castings may
be used as cast or in a heat
treated condition. Heat-treatment
345
CHAPTER 16- MATERIALS
346
CHAPTER 16- MATERIALS
16.5.6.4 SAE Standard No. 52 Alloy. This is are normally more economical than
general purpose alloy with moderate press forgings but can only be used in
strength and fair weldability. It is applications involving higher stresses.
specially suited for the production of No. 532 is stronger than No. 531 but
thin wall tubing and other sections more difficult to forge and is usually
requiring good extrusion employed only for comparatively
characteristics. simple forgings requiring highest
physical properties.
Composition of No. 52: Aluminum,
2.4 to 3.0; manganese, mm. 0.20; Composition of No. 53: Aluminum,
zinc, 0.7 to 1.3; silicon, max. 0.5; 3.0 to 4.0; manganese, mm. 0.2; zinc,
copper, max. 0.05; nickel, max. 0.03; max. 0.3; silicon, max. 0.3; copper,
other impurities, max. 0.3 per cent and max. 0.05; nickel, max. 0.005; iron,
the remainder, magnesium. max. 0.005; and tin, 4.0 to 6.0 per
cent; remainder, magnesium.
16.5.6.5 SAE Standard No. 520 Alloy. This
alloy is used for extruded bars, rods Composition of No. 531: Aluminum,
and shapes with good strength and 5.8 to 7.2; manganese, mm 0.15; zinc,
fair weldability. 0.4 to 1.5; silicon, max. 0.3; copper,
max. 0.05; nickel, max. 0.005;l and
Composition of No. 520: Aluminum, iron, max. 0.005 per cent; remainder,
5.8 to 7.2; manganese, mm. 0.15; magnesium.
zinc, 0.04 to 1.0; silicon, max. 0.03;
other impurities, max. 0.3 per cent and Composition of No. 532: Aluminum,
the remainder, magnesium. 7.8 to 9.2; manganese, mm 0.12; zinc,
0.2 to 0.8; silicon, max. 0.3; copper,
Physical Properties: Standard tension max. 0.05; nickel, max. 0.005; and
test specimens machined from solid iron, max. 0.005 per cent; remainder,
bar stock and structural shapes have magnesium.
a minimum tensile strength of 276
2 in extruded bars up to 38 mm
N/mm Composition of No. 533: Manganese,
and 262 N/mm
2 in structural shapes; a mm. 1.2; silicon, max. 0.3; copper,
yield strength of 179 N/mm
2 in the max. 0.05; and nickel, max. 0.03 pe
former and 158.6 N/mm
2 in the latter cent; remainder, magnesium.
and an elongation in 50 mm of 12 per
cent in the former and 10 per cent in 16.5.7 Nickel and Nickel Alloys
the latter.
16.5.7.1 Nickel. Nickel is noted for its
16.5.6.6 SAE Standard No. 522 Alloy. This is corrosion resistance, good electrical
an extrusion alloy used for conductivity and high heat-transfer
applications requiring maximum properties. It is used to fabricate
weldability. process equipment for handling pure
foods and drugs, electrical contact
Composition of No. 552: Manganese, parts, and radio and X-ray tube
mm. 1.2; silicon, max. 0.3; copper, elements.
max. 0.05; nickel, max. 0.03; and
calcium, 0.3 per cent; remainder, Approximate Composition:
magnesium. (Commercially pure wrought nickel)
Nickel (including cobalt) 99.4; copper,
16.5..7 SAE Standard Nos. 53, 531, 532 and 0.1; iron, 0.15; manganese, 0.25;
533 Alloys. These are forging alloys. silicon, 0.05; carbon, 0.05; and sulfur,
Nos. 53 and 533 are suitable for 0.005. (Cast nickel): Nickel, 97.0;
hammer forging. The former has copper, 0.3; iron, 0.25; manganese,
somewhat better physical properties 0.5; silicon, 1.6; and
but the latter may be readily welded carbon, 0.5.
and contains no tin. No. 533 may also
be press forged. Hammer forgings
347
CHAPTER 16- MATERIALS
16.5.7.2 Low-Carbon Nickel. A special type and instrument parts are made
of nickel that is corrosion resistant and from this alloy.
has a high ductility and heat
resistance. It lends itself well to Approximate Composition:
spinning and cold coining or forging Nickel, 66; copper, 29; iron, 0.9;
and is used in the manufacture of aluminum, 2.75; silicon, 0.5;
tubing and molds for the beverage manganese, 0.75; carbon, 0.15;
and food industries. and sulfur, 0.005.
348
CHAPTER 16— MATERIALS
349
CHAPTER 16— MATERIALS
An etching fluid ordinarily used for For some classes of work paraffin is
carbon steel consist of nitric acid, 1 used for protecting the surface
part: water, 4 parts. It may be surrounding the graduation lines
necessary to vary the amount of which are to be etched. The method
water, as the exact proportion of application consists of melting the
depends upon the carbon in the steel paraffin and raising its temperature
and whether it is hard or soft. For hard high enough so that it will flow freely;
steel, use nitric acid, 2 parts; acetic then the work is held at a slight angle
acid, 1 part. For high-speed steel, and the paraffin is poured on its upper
nickel or brass, use nitro-hydrochloric surface. The melted paraffin forms a
acid (nitric, 1 part; hydrochloric, 4 thin protective coating.
parts). For high-speed steel it is
sometimes better to add a little more
nitric acid. For etching bronze, use 16.6.2 Coloring Metals.
nitric acid, 100 parts; muriatic acid, 5
parts. For brass, nitric acid, 16 parts; 16.6.2.1 General Requirements in the
water, 160 parts; dissolve 6 parts Coloring of Metal Surfaces. Copper
potassium chlorate in 100 parts of is more susceptible to coloring
water; then mix the two solutions and processes and materials than any of
apply. the other metals and hence the alloys
containing large percentages of
A fluid which may be used either for copper are readily given various
producing a frosted effect or for deep shades of copper (or none at all) can
etching (depending upon the time it is be given various colors, but not as
allowed to act) is composed of 1 easily as if copper were the principal
ounce sulfate of copper (blue vitriol); ingredient, and the higher the copper
1/4 ounce alum; 1/2 teaspoon of sale; content, the more readily can the alloy
1 grill of vinegar, and 20 drops of nitric be colored. The shades, and even
acid. For aluminum, use a solution the colors, can be altered by varying
composed of alcohol, 4 ounces; acetic the density of the solution, its
acid, 6 ounces; antimony chloride, 4 temperature and the length of time the
ounces; water, 40 ounces. object is immersed. They can also be
altered by finishing the work in
Various acid-resisting materials are different ways. If a cotton buff is used,
used for covering the surfaces of steel one shade will be produced.
rules etc., prior to marking off the lines
on a graduating machine. When the
graduation lines are fine and very
closely spaced, as on machinists
scales which are divided into
hundredths or sixty-fourths, it is very
important to use a thin resist that will
cling to the metal and prevent any
under-cutting of the acid; the resist
should also enable fine lines to be
drawn without tearing or crumbling as
the tool passes through it. One resist
that has been extensively used is
composed of about 50 per cent of
asphaltum, 25 per cent of beeswax,
and in addition, a small percentage of
Burgundy pitch, black pitch, and
turpentine. A thin covering of this
resisting material is applied to the
clean polished surface to be
graduated and after it is dry, the work
is ready for the graduating machine.
350
CHAPTER 17— INSTRUMENTATIONS
Chapter 17
INSTRUMENTATIONS
The purpose of this standard is to establish a a. The standard is suitable for use whenever
uniform means of designating instruments and any reference to an instruments or to a
instrumentation systems used for the measurement control system function is required for the
and control. To this end a designation system that purpose of symbolization and
includes symbols and an identification code is identification. Such references may be
presented. required for the following uses as well as
the other:
Section 2.0 Scope Design Sketches
2.1 General
Teaching examples
a. The procedural needs of various users are
Technical papers, literature, and discussions
different. The standard recognizes these
instrumentation system diagrams, loop diagrams,
needs, when they are consistent with the Logic diagrams
objectives of the standards, by providing
Functional descriptions
alternative symbolism methods. A number
Flow diagrams : Process, Mechanical, Engineering,
of examples are provided for adding
System, Piping (Process) and Instrumentation
information or simplifying the symbolism
Construction drawings
as desired. Specifications, purchase orders, manifest, and other
lists
b. Process equipment symbols are not part
Identification (tagging) of instruments and control
of this standard, but are included only to
functions
illustrate application s of instrumentation
Installations, operating and maintenance instruction,
symbols.
drawings and records.
2.2 Application to Industries
b. The standard is intended to provide
sufficient information to enable anyone
a. The standard is suitable for use in the
reviewing any document depicting process
chemical, petroleum, power generation,
measurements and control (who has a
air-conditioning, metal refining, and
reasonable amount of process knowledge)
numerous other process industries.
to understand the means of measurement
and control of the process. The detailed
b. Certain fields, such as astronomy, knowledge of a specialist in
navigation and medicine, use very instrumentation is not a prerequisite to this
specialized instruments that are different understanding.
from the conventional industrial process
instrument. No specific effort was
2.4 Application to Classes of Instrumentation
requirements of those fields. However it is
and to Instrument Functions
expected the standard will be flexible
enough to meet the many of the needs of
The symbolism and identification methods
special fields.
provided in this standard are applicable to all
classes of process measurements and control
instrumentation. They can be used not only to
described discrete instrument and their
functions, but also to describe the analogous
351
CHAPTER 17— INSTRUMENTATIONS
functions of the system which are variously Behind the Panel A term applied to a location that
—
termed “shared display”, “shared control”, is within an area that contains (1) the instrument
“distributed control”, and “computer control”. panel, (2) its associated rack-mounted hardware, or
(3) is enclosed with the panel. Behind the panel
2.5 Extend of Functional Identification devices are not accessible for the operator; normal
use, and are not designated as local or front-of-panel-
The standard provides for the identification and mounted. In a very broad sense, “behind the panel” is
symbolization of the key function of an equivalent to “not normally accessible to the operator”.
instrument. Addition details for the instrument
are better described in a suitable specification, Binary A term applied to a signal or device that has
—
data sheet, or any document intended for those only two discrete positions or states. When used in its
requiring such details. simplest form, as in “binary signal” (as opposed to
“analog signal”), the term denotes an “on-off” or “high-
2.6 Extend of Loop Identification low” state, i.e., one which does not represent
continuous varying quantities.
The standard covers the identification of an
instrument and all other instruments or control Board — Synonym for panel.
functions associated with it in a loop. The user is
free to apply additional identification by serial
— Bubble the circular symbol used to denote and
—
number, unit number, area number, plant identify the purpose of an instrument or function. It
number, or by other means. may contain a tag number. Synonym for balloon.
352
CHAPTER 17— INSTRUMENTATIONS
actuated ON-OFF valve or self-actuated check valve, nor on a panel or console, nor it is mounted in a
that directly manipulated the flow of one or more fluid control room. Local instruments are commonly in the
process streams. vicinity of a primary element or a final control element.
The world “field” is often used synonymously with
It is expected that use of the designation “hand control local.
valve” will be limited to hand-actuated require
identification as an instrument. Local Panel A panel that is not a central or main
-
An instrument which changes a sensor’s output to a Loop A combination of two or more instruments or
—
standard signal is properly designated as a control functions arranged so that signal pass from
transmitter, not a converter. Typically, a temperature one to another fort he purpose of measurement and/or
element (TE) may connect to a transmitter (TT), not to control of a process variable.
a converter (TY).
Manual Loading System A device or function
—
A converter is also ref erred to as a transducer; having a manually adjustable output that is used to
however, “transducer’ is a completely general term, actuate one or more remote devices. The station odes
and its use specifically for signal conversions is not not provide switch
ng between manual and automatic
1
recommended. control modes of a control loop (see controller and
control station). The station may have integral
Digital A term applied to a signal or device that used
—
indicators, lights, or other features. It is also known as
binary digits to represent continuous valve or discrete a manual station or a manual loader.
states.
Measurement The determination of the existence or
—
control loop. Often the final control element is a control analyzer, indicator, or alarm. Monitor can also be used
valve. as a verb.
Function — The purpose of, or an action performed Monitor light — Synonym for pilot light.
by, a device.
Panel — A structure that has a group of instruments
Identification The sequence of letters of digits, or
— mounted on it, houses the operator-process interface,
both, used to designate an individual instrument or and is chosen to have a unique designation. The
loop. panel may consist of one or more sections, cubicles,
consoles, or desks. Synonym for board.
Instrument A device used directly or indirectly to
—
measure and/or control a variable. The term includes Panel-Mounted A term applied to an instrument that
—
primary elements, final control elements, computing is mounted on a panel r console and is accessible for
devices, and electrical devices such as annunciators, an operator’s normal use. A function that is normally
switches, and pushbutton. The term does not apply to accessible to an operator in a shared-display system
parts (e.g., a receiverbellows or a resistor) that are is the equivalent of a discrete panél-rhounted device.
internal components of an instrument.
Pilot Light A light that indicates which of a number
—
353
CHAPTER 17— INSTRUMENTATIONS
Primary Element - Synonym for sensor. control information from a number of sources at the
command of the operator.
Process Any operation or sequence of operations
-
involving a change of energy, state, composition, Switch A device that connects, disconnects, selects,
—
dimension, or other properties that may be defined or transfers one or more circuits and is not designated
with respect to a datum. as a controller, a relay, or a control valve. As a verb,
the term is also applied to the functions performed by
Process Variable Any variable property of a
— switches.
process. The term process variable is used this
standard to apply to all variables other than instrument Test Point — A process connection to which no
signals. instruments is permanently connected, but which is
intended for the temporary or intermittent connection
Program A repeatable sequence of actions that
—
of an instrument.
defines the status of outputs as a fixed relationship to
a set of inputs. Transducer — A general term for a device that
receives information in the form of one or more
Programmable Logic Controller A controller,
— physical quantities, modifies the information and/or its
usually with multiple inputs and outputs, that contains form, if required, and produces a resultant output
an alterable program. signal. Depending on the application, the transducer
can be a primary element, transmitter, relay, converter
Relay — A device whose functions is to pass on or other device. Because the term “transducer” is not
information in an unchanged form or in some modified specific, its use for specific applications is no
form. Relay is often used to mean computing device. recommended.
The latter term is preferred.
Transmitter A device that senses a process variable
—
The term “relay” also is applied specifically to an through the medium of a sensor and has an output
electric, pneumatic, or hydraulic switch that is actuated whose steady-state value varies only as a
by a signal. The term is also applied to functions predetermined function of the process variable. The
performed by a relay. sensor may or may not be integral with transmitter.
senses the value of a process variable, and that alphanumeric code or tag number as
assumes a corresponding, predetermined, and
shown in Fig. 1. The loop identification
intelligible state or output. The sensor may be
party of the tag number generally is
separate from or integral with another functional common to all instrument or functions of
element of a loop. The sensor is also known as a the loop. A suffix or prefix may be added
detector of a primary element.
to complete this identification. The typical
identification is shown Figure 1.
Set Point An input variable that sets the desired
—
354
CHAPTER 17- INSTRUMENTATIONS
measured or initiating variable) and one or inscribed TIC-3 and one inscribed TSH_3.
more succeeding-letters (identifying the The instrument would be designated
function performed). TIC/TSH-3 for all uses in writing or
references. If desired, however, the
b. The functional identification of an abbreviation TIC-3 may serve for general
instrument is made according to the identification or for purchasing, while TSH
function and not according to the 3 may be used for electric circuit
construction. Thus, a differential-pressure diagrams.
recorder used for flow measurement is
identified by FR; a pressure-actuated g. The number of functional letters grouped
switch connected to the output of a for one instrument should b e kept to a
pneumatic level transmitter are identified minimum according to the judgment of the
by LI and LS, respectively. use. The total number of letters within one
group should not exceed four. The
c. In an instrument loop, the first-letter of the number within a group may be kept to a
functional identification is selected minimum by;
according to the measure of initializing
variable, and not according to the h. Arranging the functional letters into
manipulated variable. Thus a control valve subgroups. This practice is described in
varying flow according to the dictates of a Section 4.2.6 for instruments having more
level controller is an LV, not an FV. than one measured variable or input, but it
may also be used for other instruments.
d. The succeeding-letters of the functional
identification designate one or more Section 5.0 Drawings
readout or passive functions and/or output
functions. A modifying-letters may be
5.1 Cautionary Notes
used, if required in addition to one or more
other succeeding letters. Modifying letters
a. If a given drawing or set of drawings, uses
may modify either a first-letter or
graphic symbols that are similar or
succeeding-letter, as applicable. Thus,
identical in shape or configuration and that
355
CHAPTER 17— INSTRUMENTA11ONS
have different meanings because they are (12) Electric binary signal
taken from different standards, then
adequate steps must be taken to avoid Note: ‘or’ means user’s choice. Consistency is
misinterpretation of the symbols used. recommended.
These steps may be to use caution notes,
reference notes, comparison charts that *The following abbreviations are suggested to
illustrate and define the conflicting designations may also be applied to purge fluid
symbols, or other suitable means. This supplies.
requirement is especially critical in cases
where symbols taken from different AS — Air Supply HS- Hydraulic Supply
disciplines are intermixed and their
misinterpretation might cause danger to IA — Instrument Air NS — Nitrogen Supply
personnel or damage to equipment.
PA — Plant Air SS — Steam Supply
b. The titles Simplified Diagrams, Conceptual
Diagrams and Detailed Diagrams were ES — Electric Supply WS — Water Supply
chosen to represent a cross section of
symbol usage not any particular generic GS — Gas Supply
document.
The supply level may be added to the instrument
c. The line symbols on Section 6.2 offer supply line, e.g., AS 100, a 100-psig air supply; ES-
—
“user’s choice” alternative electrical 24 DC, a 24-volt direct current power supply.
symbols and optional binary symbols. The
subsequent examples use on consistent
**
The Pneumatic signal symbol applies to a signal
set of these alternatives and apply the using any gas as the signal medium. If the gas other
binary options. This was done for than air is used, the gas may be identified by a note on
consistency of appearance of the the signal symbol or otherwise.
standard. **
The Electromagnetic phenomena include heat, radio
It is recommended that the user choose either the wages, nuclear radiation and light.
dashed line electrical symbol or the triple crossed
hatch symbol and apply it consistently. The optional
binary (on-off) symbols are available for those
applications where the user finds it necessary to
distinguish between analog and binary signals. If in the
user judgment, the application does not require such
differentiation, the reverse slash may be omitted from
on-off signal line symbols. Consistency is
recommended on a given set of documents.
356
CHAPTER 17— INSTRUMENTAflONS
Primary Auxiliary
location location
*** normally Field *** normally
accessible to mounted accessible to
operator operator
1 2 3
* IPI**
Discrete
instrumental
4 5 6
Shared display,
shared control
7 8 9
Compur
10 11 12
Programmable
logic control
*
Symbol size may vary according to the user’s needs and the type of document. A suggested square and circle size for large
diagrams is shown above, consistency is recommended.
**
Abbreviations of the user’s choice such as IP1 (Instrument Pannel #1), lC2 (Instrument Console #2), CC3 (Computer Console
#3), etc. may be used when it is necessary to specify instrument of function.
Normally inaccessible or behind-the-panel devices or functions may be depicted by using the same symbols but with dashed
horizontal bars, i.e.
13 14
EEO 15
2584-23
‘—‘ Instrumental sharing common
Instrumental with long tag number housing *
16 17 18 **
357
CHAPTER 17- INSTRUMENTATIONS
Further information may added adjacent to the body symbol either by note or code number.
358
CHAPTER 17— INSTRUMENTATIONS
I 2 3 4
Preferred for
diaphragm assembled
with pilot *.Assembly is
With or without actuated by one with input Preferred Optimal
positioner (shown typically with alternative alternative
or other pilot electric input)
Diaphragm, spring opposed,
Diaphragm, spring-opposed with positioner ** and over riding pilot valve that
or unspecified actuator pressurizes diaphragm when actuated
5 6 7
LiJ
359
CHAPTER 17— INSTRUMENTATIONS
11 12 13
Preferred alternative. A
bubble with instrument tagging,
E.G. TY-1, may be used instead Single-acting cylinder
of the interlock symbol (Implied l/P)
Valve actuator
Dual solenoids switching 4-way with atached electro-pneumatic
Hydrolic valve Electrohydraulic converter
17 18 19
(Manual (Remote
reset) reset)
/
Latch-type actuator with reset
(shown typically for solenoid
actuator and typically with electric For pressure relief or sefety valves
signal for remote reset, with only: denotes a spring, weight,or Hand actuator or
manual reset alternative) integral pilot handwheel
360
CHAPTER 17 INSTRUMENTATIONS
1 2 — (UPSTREAM
‘ ALTERNATIVE)
3, (DOWNSTREAM
ALTERNATIVE)
Automatic regulator with Automatic regulator Indicating variable area meter with
integral flow indication without indication integral manual throttle valve
4 5 6
0
Restriction orifice drilled in valve
Restriction orifice (orifice plate, (instrument tag number may be
capillary tube or multi-stage type, omitted if valve is otherwise Flow sight glass, plain or with
etc.) in process line identified) paddle wheel, flapper, etc.
8 9
li
361
CHAPTER 17— INSTRUMENTATIONS
17.6.6 Symbols for self-actuated regulators, valves, and other devices (continued).
PcV
2
362
CHAPTER 17- INSTRUMENTATIONS
17.6.6 Symbols for self-actuated regulators, valves, and other devices (continued).
363
CHAPTER 17— INSTRUMENTATIONS
I 2 3
V C
4 5 6
Four-way valve,
Any valve, fail locked Any valve, fail
fail open to paths A-C and
(position does not change) indeterminate
D-B
The failure modes indicated are those commonly defined by the term, “shelf-position”. As an
aLternative to the arrows and bars, the following abbreviations may be employed:
FO Fail Open
-
FC Fail Closed
-
Fl Fail Indeterminate
-
364
CHAPTER 17 — INSTRUMENTATIONS
1
A 2 3
C’)
Cl)
>-
<
<
rERNACE URZ
uJ
C-)
0
r
C-)
Cl)
c
w
Cl)
Conductivity cell connected to
point 5 of multipoint scanning Inline consistency
conductivity recorder transmitter
Dl 2 3
SOURCE
CONVEYOf
s
C)
:
‘ ?Dsitftflttèr; Rdio-tjpe density Specific gravity
differential-pressure elements connected to transmitter,
type, externally connected recorder on panel flow-through type
Use of letter C and D defined on user’s legend sheet
365
CHAPTER 17— INSTRUMENTATIONS
—;- 2 3
Ui
0
<
-I
0
>
II
‘
Office plate with vena contracta,
radius or pipe taps connected to
Orifice plate with vena differential-pressure-type flow Radius tap test connections
contracta taps transmitter without orifice plate
7 8 9
-)
E1’ -
I
366
CHAPTER 17— NSTRUMENTATIONS
I 11 12
F 13 14 15
—-[U——- \
>iJ
L, -)___
367
CHAPTER 17- INSTRUMENTATIONS
22 23 24
F
.
—
0
C)
I
z
LU
z
C.)
Ui
0 -
1
K 2 3
d Clock
Multipoint on-off time sequencing
programmer point 7
Time-schedule controller,
analog type, or self contained
function generator
368
CHAPTER 17— INSTRUMENTATIONS
369
CHAPTER 17— INSTRUMENTATIONS
13 14 15
I 18B
Ui
-J
i 2
M
©s CONVEYOR
2 3
0
< With pressure lead line Line-mounted
> Pressure indicator,
direct-connected Pressure Indicator connected t diaphragm seal with filled system
4 5 6
Cl)
U)
Ui
0
370
CHAPTER 17— INSTRUMENTATIONS
1 2
Q 3
%5N fN
LIGHT ( ) LIGHT 1 ) SCONVEYOR
SOURCE SOURCE
\/SCONVEYOR ‘-‘<%CONVEYOR
0
LU
LU
0
Speed transmitter
1
T 2 3
:
.
C.
LU
371
CHAPTER 17- INSTRUMENTATIONS
4 5 6
RTD(IF
CABLE
r1
Dual or duplex thermocouple
connected to multipoint indicator Thermal-radiation type
and multipoint scanning recorder for different elevations, temperature indicator,
(tag element TE-1 5-7/16-2) with well in tank self-contained
13 14 15
r3©
372
CHAPTER 17— INSTRUMENTATIONS
Alternative 1 Alternative 1
(treated as disbnct loops) Aftemative2 (treated as distfr)Ct lOOPS)
-
- -
- Alternative 2 - - -
Low-flow switch actuating one point of a Level signal received by one point of a
multipoint of multivariable alarm annunciator multipoint multivariable indicator
I 2 SEISMIC
0
Co
z
cE
-j
373
CHAPTER 17- INSTRUMENTATIONS
1 2 3
CONVEYOR
w
Ui
C,
0
U
0
I
4 5 6
0
E DRIVEN
F MACHINE
a
374
APPENDICES
375
APPENDIX A
376
APPENDIX B
‘1 —
FIG. B
1 ELEVATION OF TYPICAL DIESEL ENGINE PLANT
377
APPENDIX D
Partially Compressed
Car Oil Buffer
FIG. D
1 FIG. D
2
Bottom terminal
Fully compressed
oil or spring buffer
or solid bumper
378
_______________
APPENDIX E
HOISTWAY ACCESS—DIAGRAMMATIC
REPRESENTATION
Note:
With the landing means, it is only necessary to open the door of any one or several cars at a floor.
379
APPENDIX F
27 in (636 mm)
above nose line
of steps
tread
6112 in
610 in
(165 mm)
max.
: 16 in. (406 mm)min.
40 in. (1016 mm) max.
-fri (165 mm) ‘-4
max.
4 Step tread width + 13 in (330 mm) max.
380
APPENDIX F
White
CAUTION
Black
yellow
Hold Handrail
Attend Children
Avoid Sliders
FIG. F
2 ESCALATOR CAUTION SIGN
381
_______
APPENDIX F
1 in (25 mm)
mm.
>
Width exposed
treadway
382
APPENDIX F
Sh.. Door
Operator
Clotob
Dototy odD.
Fig. F
4 TRACTION V.V. GEARLESS ALEVATOR
383
APPENDIX F
J.dc Casing
II
II
384
APPENDIX G
1. The ISO metric series for the basic thickness of sheet and
diameters of wire is established on the series of preferred
numbers set out in ISO Recommendation R 3-Preferred
numbers. Series of preferred numbers. See Table G
.
1
NOTE: The equivalent inch values for sizes above 0.25 mm are
given to an accuracy close to, or better than, one part in one
thousand. This accuracy would be appropriate to practical limits of
size associated with a tolerance of I per cent of the size. For sizes
smaller than 0.25 mm, five places of decimals appear adequate for
any likely method of direct measurement in inches. The true
mililmetre basic sizes should be used if it s desired to compute
limits of size in any alternative characteristic, such as mass or
electrical resistance.
385
APPENDIX G
Table G
1
TABLE OF BASIC SIZES
NOTE: Preference should be given to sizes in the R 10, R 20 and R 40 series, in that order.
386
APPENDIX G
Table G,
TABLE OF BASIC SIZES
(continued)
NOTE: Preference should be given to sizes in the R 10, R 20 and R 40 series, in that order.
3.35 0.131 9
3.55 3.55 0.1398
3.75 0.147 6
4.00 4.00 4.00 0.1575
4.25 0.167 3
4.50 4.50 0.1772
4.75 0.1870
5.00 5.00 5.00 0.1969
5.30 0.208 7
5.60 5.60 0.220 5
6.00 0.236 2
6.30 6.30 6.30 0.248 0
6.70 0.263 8
7.10 7.10 0.279 5
7.50 0.295 3
8.00 8.00 8.00 0.3150
8.50 0.334 6
9.00 9.00 0.3543
9.50 0.3740
10.00 10.00 10.00 0.393 7
10.60 0.4173
11.20 11.20 0.440 9
11.80 0.4646
12.50 12.50 12.50 0.492 1
13.20 0.519 7
14.00 14.00 0.551 8
15.00 0.590 6
16.00 16.00 16.00 0.629 9
17.00 0.669 3
18.00 18.00 0.708 7
19.00 0.748 0
20.00 20.00 20.00 0.787 4
387
APPENDIX H
WIRE GAGES
1 WIRE GAGES
Table H
.460 11.7 .3938 10.0 .454 11.5 .454 11.5 400 10.2 .4062
0 000
10.4 .3625 9.2 .425 10.8 .425 10.8 372 9.4 .3750
000 .410
9.3 .3310 8.4 .380 9.7 .380 9.7 348 8.8 .3437
00 .365
.325 8.3 .3065 7.8 .340 8.6 .340 8.6 324 8.2 .3125
0
.289 7.3 .2830 7.2 .300 7.6 .300 7.6 .227 5.77 .300 7.6 .2812
6.5 .2625 6.7 .284 7.2 .284 7.2 .219 5.6 .276 7.0 .2656
2 .258
.229 5.8 .2437 6.2 .259 6.6 .259 6.6 .212 5.38 .252 6.4 .2500
3
5.2 .2253 5.7 .238 6.0 .238 6.0 .207 5.26 .232 5.9 .2344
4 .204
.182 4.6 .2070 5.3 .220 5.6 .220 5.6 .204 5.18 .212 5.4 .2187
5
.162 4.1 .1920 4.9 .203 5.2 .203 5.2 .201 5,11 .192 4.9 .2035
6
3.7 .1770 4.5 .180 4.6 .180 4.6 .199 5.05 .176 4.5 .1875
7 .144
3.3 .1630 4.1 .165 4.2 .165 4.2 .197 5,00 .160 4.1 .1719
8 .128
.114 2.91 .1463 3.77 .148 3.76 .148 3.76 .194 4.93 .14.4 3.66 .1562
9
.102 2.59 .1350 3.43 .134 3.43 .134 3.43 .191 4.85 .128 3.25 .1406
10
.091 2.30 .1205 3.06 .120 3.05 .120 3.05 .188 4.78 .116 2.95 .1250
11
.081 2.05 .1055 2,68 .109 2.77 .109 2,77 .185 4.70 .104 2.64 .1094
12
1.83 .0915 2.32 .095 2.41 .095 2.41 .182 4.62 .092 2.34 .0937
13 .072
14 .064 1.63 .0800 2.03 .083 2.11 .083 2.11 .180 4.57 .080 2.03 .0781
.057 1.45 .0720 1.83 .072 1.83 .072 1,83 .178 4.52 .072 1.83 .0703
15
.051 1.29 .0625 1.59 .065 1.65 .065 1.65 .175 4.45 .064 1.63 .0625
16
17 .045 1.15 .0540 1.37 .058 1.47 .058 1.47 .172 4.37 .056 1.42 .0562
1.02 .0475 1.21 .049 1.24 .049 1.24 .168 4.27 .048 1.22 .0500
18
.036 0.91 .0410 1.04 .042 1.07 .040 1.02 .164 4.17 .040 1.02 .0437
19
0.81 .0348 0.88 .035 0.89 .035 0.89 .161 4.09 .036 0.91 .0375
20 .032
0.72 .0317 0.81 .032 0.81 .0315 0.80 .157 3.99 .032 0.81 .0344
21 .0285
.0253 0.64 .0286 0,73 .028 0.71 .0295 0.75 .155 3.94 .028 0.71 .03 12
22
0.57 .0258 0,66 .025 0.64 .0270 0.69 .153 3.89 .024 0.61 .0281
23 .0226
0.51 .0230 0.58 .022 0.56 .0250 0.64 .151 3,84 .022 0.56 .0250
24 .0201
.0179 0.45 .0204 0.52 .020 0.51 .0230 0.58 .148 3.76 .020 0.51 .0219
25
.0159 0.40 .0181 0.46 .018 0.46 .0205 0.52 .146 3.71 .018 0.46 .0187
26
.0142 0.36 .0173 0.439 .016 0.41 .01875 0.48 .143 3.63 .0164 0.42 .0172
27
.0126 0.32 .0162 0.411 .014 0.36 .0 1650 0.42 .139 3.53 .0148 0.38 .0156
28
.0113 0.29 .0 150 0.381 .013 0.330 .01550 0.394 .134 3.40 :0136 0.345 .0141
29
0.25 .0 140 0.356 .012 0.305 .01 375 0.349 .127 323 .0124 0.315 .0125
30 .0100
.0089 0.227 .0132 0.335 .010 0.254 .01225 0.311 .120 3.05 .0116 0.295 .0109
31 ‘
.0080 0.202 .0128 0.325 .009 0.229 .01125 0.286 .115 2.92 .0108 ‘‘0274 .0101
32
.0071 0.180 .0118 0.300 .008 0.203 .01025 0.260 .112 2.84 .0100 0.254 .0094
33
34 .0063 0.160 .0104 0.264 .007 0.178 .00950 0.241 .110 2.79 .0092 0.234 .0086
.0056 0.143 .0095 0.241 .005 0.127 .00900 0.229 .108 2.74 .0084 0.213 .0078
35
0.127 .0090 0,229 .004 0.102 .00750 0.191 .106 2:69 .0076 0.193 .0070
36 .0050 ‘
.0045 0.113 .0085 0.216 00650 0.165” .103 2.62 .0068 0.173 .0066
37
.0040 0.101 .0080 0.203 00575 0.146 .101 2.57 .0060 0.152 .0062
38
.0035 0.090 .0075 0.191 00500 0.127 .099 2.51 .0052 0.132
39
40 .0031 0.080 .0070 0.178 00450 0.114 .097 2.46 .0048 0.122
388
APPENDIX I
TEST METHOD
HYDRAULIC TEST
Test Method — Hydraulic test shall be carried out using a HYDROSTATIC TESTER with the following
standard values to be used as criteria for this test.
(M.W.C.)
6 - 25 4.90 (500)
32 - 80 6.86 (700)
100 - 300 9.80 (1000)
All pipes, when subjected to hydraulic test, shall be able to withstand the required hydraulic test pressure.
389
APPENDIX I
PHILIPPINE NATIONAL STANDARD SIZES OF BLACK AND HOT DIPPED ZINC-COATED STEEL PIPE
FOR ORDINARY USES
Black and hot-dipped zinc-coated (galvanized) longitudinally welded steel pipes are generally classified as follows:
a) Heavy series
b) Medium series
c) Light series 1
d) Light series 2
Table Ii
STEEL PIPES DIMENSIONS AND WEIGHT OF HEAVY SERIES
390
APPENDIX I
Table 12
STEEL PIPES DIMENSIONS AND WEIGHT OF MEDIUM SERIES
391
APPENDIX I
Table 13
STEEL PIPES DIMENSIONS AND WEIGHT OF LIGHT SERIES I
Table 14
STEEL PIPES DIMENSIONS AND WEIGHT OF HEAVY SERIES
392
APPENDIX J
Philippine National Standard (PNS) Specification for Unpiasticized Polyvinyl Chloride (uPVC) Electrical Conduit Outside
Diameter and Wall Thickness
The conduit shall conform to the outside diameter and wall thickness specified in Table J
1 when tested in accordance with
PNS/lSO 3126
Unit: mm
Physical and Mechanical Properties — The conduit shall conform to the physical and mechanical properties specified in Table J
2
Table J
— PHYSICAL AND MECHANICAL PROPERTIES
2
393
APPENDIX K
Class 640 — For maximum working pressure of 640 each pipe shall be proof-tested to 420 mm of water column
kPa for a maximum period of five (5) seconds in accordance
Class 800 — For a maximum working pressure of 800 with AWWA C 900. No proof test is required for sizes 50
kPa mm and 75 mm.
Class 1000 For a maximum working pressure of
—
1000 kPa 4.2 Tensile Properties The test specimen shall have
—
Class 1280— For a maximum working pressure of the following minimum tensile properties at 28°C
1280 kPa when tested in accordance with Annex B.
394
0 0 0 0 0
6 1. 91.+ C. I.+ L(OL. 99•8 t7C i 60
0 0 0 0 0
W t709 I. V 1.+ 061.1. . I_+ I.96 0• I.+ 9LL o 90+ 09
0 0 0 0 0
9 1. £9t 1. £• 1. 1.1•0l. L. 1. 99.9 60+ 869 (0+
0 0 0 0 0
. 1.+ 96 0• I.+ 69L 60+ 0.9 9•0+ 00
0 0 0 0 0
£90I. L. 1.+ L98 60+ 69 90 99•9 9•0+ 081.
0 0 0 0 0
96 0• I.+ 9L 60 91. 9 (0+ 96t 90+ 091.
0 0 0 0 0
1. 60+ 19•9 90 8C9 (0+ t7Ct Li. 1 90+ OIv 1.
0 0 0 0 0
0• 1. 9L 8O+ 9(0+ [9ji 9•0+ L9E 91. 1-
0 0 0 0 0
6O+ 9.9 9O 79 L0 •j7 9•0+ 147C j7 i.; 01.1.
0 0 0 0 0
90 (0+ 9t 9•0+ 9VE 90+ 6L [•I. 06
0 0 0 0 0
L0+ 9•0+ L9C 90 99 9•0+ 60 91
0 0 0 0 0
L9i 9•0+ 90 oot 90 90 co £9
0 0 0 0 0
90 0L 90 t’6 90 8C I. g•o; 09
0 0 0 0 0
96 90+ 9C 06 I. t’9 1. 90 0,
0 0 0 0 0
90 L l’•O+ 89• 1. t1•0+ 9 1. c2. I. 90
0 0 0 0
t70 991. LV I. 61.1. 90 1
0 0 0
9t L. LVL. 90 C.o+ 0
0 0
V0 91. I. 90 F 91.
0
90
0
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sseu)p!qJ SSOUO!LJ Jejewei
o . Io Io ‘cweo •a•o
IIM hEM hEM hEM 9P!SflO
BdI 08 1. EdN 000 1. EdN 009 EdN 009 BOUEJeIOI. IEU! WON
sseu)piLa hEM Jeewe!cI OP!SlflO
WVI ‘SNOISN]vlIa 3dId I oqe
DAd pezpisedun
1 XIuNdddV
APPENDIX L
Continuation of Table L
1
396
APPENDIX M
Table M-1
397
APPENDIX M
398
APPENDIX M
Table M-2
399
APPENDIX M
400
APPENDIX M
Table M-3
401
APPENDIX M
402
APPENDIX M
Table M-4
REFRIGERANT 11: PROPERTIES OF LIQUID AND SATURATED VAPOR
403
APPENDIX M
Table M-5
REFRIGERANT 12: PROPERTIES OF LIQUID AND SATURATED VAPOR
5
404
APPENDIX M
Table M-5 (continued)
405
APPENDIX M
Table M-6
REFRIGERANT 22: PROPERTIES OF LIQUID AND SATURATED VAPOR
406
APPENDIX M
Table M-6 (continued)
407
APPENDIX M
Table M-7
REFRIGERANT 22: PROPERTIES OF SUPERHEATED VAPOR
6
408
APPENDIX M
409
APPENDIX M
410
APPENDIXM
Table M-8
REFRIGERANT 502: PROPERTIES OF LIQUID AND SATURATED VAPOR
411
APPENDIX M
Liquid Fuels
Liquid Fuels
BTUIIb
Gasoline 20 620 35 400
Diesel 19650 38600
Fuel Oil 18600 41 800
Kerosene 19800 36500
LPG (1 kg = 1.86L) 21180 27100
Augas 20 950 35 200
Auturbo 19 800 36 500
Naptha 20 620 35 400
Waste Oil 18600 41800
Methanol 9 600 17 800
Ethanol 12800 23600
Coco-oil 15 750 33 900
Solid Fuels
BTU!Ib K,J!kg
Coal 9 000 20 900
Bagasse (50% moisture) 4 000 9 300
Wood Waste (30% moisture) 4 000 9 300
Rice Hull 6 000 14 000
Coco-Shell 8 630 20 100
Coco Husk 7400 17200
Gaseous
BTUIcu.ft KJIcu. metre
Natural Gas 1 020 37 975
Biogas 650 24 200
Electricity
BTUIKWH KJ/KWH
at 33% Thermal 10340 10909
412
_______________________________
_______________________________
______________________________
________________________________
_____________________________
________________________________________
_____________________________
___________________________
_____________ ___________________ ____________________________________
_____________________________________
_____________________________________
________________________________________
__________________________________________________________________________
________
______________________________________________________________________________
______________________________________________________
APPENDIX 0
1. Name of Establishment:
2. Address:
3. Owner/Manager and Address:
5. Plants to be submitted: Submit (in quadruplicate) the foundation plan with design, installation and location plans of the boiler!
Pressure vessel. The plans shall be prepared, signed and sealed by a Professional Mechanical Engineer. Plan shall also
Bear the name and signature of owner or manager of the plant. The working drawing of the boiler/pressure vessel shall be
submitted together with the First Inspection Report.
6. Boiler/Pressure vessel Data:
(a) Manufacturer:
(b) Type: (c) Serial Number:
(d) Place of Origin: (e) Date of Make:
(If unknown, approximate)
(f) Heating Surface: (g.) Max A.W.P.
(h) Horsepower/Cubic Feet:
Application No.
‘Plan Fee:
‘P.R. No. Date:
‘Date Received:
‘Received by:
413
__________
APPENDIX P
H
MECHANICAL PERMIT
DATE OF APPLICATION DATE ISSUED
Li OTHERS (SPECIFY)
PROPOSED DATE EXPECTED DATE
OF INSTALLATION OF COMPLETION
TOTAL INSTALLATION COST_____________________________ PREPARED BY
-
THIS PERMIT MAY BE CANCELLED OR REVOKED PURSUANT TO SECTIONS 305 & 306 OF THE NATIONAL BUILDING CODE*
414
APPENDIX 0
REVIEWED:
\-
CHIEF, PROCESSING DIV/SEC.
-,
BOX 5 (TO BE ACCOMPLISHED BY THE DIVISION/SECTION CONCERNE
D)
PROGRESS FLOW \
NOTED IN OUT
CHIEF, PROCESSING DIVISION/SECTION ACTION/REMARKS PROCESSED BY
DATE
j TIME DATE TIME
RECEIVING AND RECORDING
MECHANICAL
____
____
____
____
___
APPLICANT
ADDRESS
RES. CERT. NO. DATE ISSUED PLACE ISSUED
P.T.R. NO. DATE ISSUED PLACE ISSUED
SIGNATURE TAN.
BOX 7
“OF. MECH. ENGINEER PRC. REG. NO
IN-CHARGE OF INSTALLATION
PRINT NAME
ADDRESS
SIGNATURE TAN.
415
3
R puIiIir of fIe fltItpptnc
Irofcgsiona1 3Regu{afton QInmmtstnn
,iftttn tht
Board of Mechanical Engineering
Resolution No. 06
Series of 2003
PREAMBLE
ant profession. It is also a
Engineering is a profession as old civilization. It is not only and import
learned one.
ize that their work has a direct
The Members of the Mechanical Engineering professional recogn
and vital impact on the quality of life of the people.
with public interest for it affects the
The services that Mechanical Engineers provide is impressed
, fair impartial and just in dealing
health, safety and welfare of the people, hence, they should be honest
not only with their clients but also with their fellowmen.
profession by observing a standard
As a professional, the Mechanical Engineer must practice his
les of ethic and professional conduct
of professional behavior that requires strict adherence to the princip
provided by the Code of Ethics of their profession.
FUNDAMENTAL CANONS
shall:
Mechanical Engineers in the fulfillment of their professional duties,
in the performance of their pro
1. Hold paramount the safety, health, and welfare of the public
fessional duties
Rule 1. The mechanical engineer shall, in the practice of his profession, be guided by the Golden
Rule, the ideals of service to man and his environment, and the need to secure unwaver
ing public confidence, integrity and humanity.
Rule 2. The mechanical engineer shall maintain the proper professional fee for his profession,
observe the standards of professional practice, safeguard the dignity, and reputation of
his colleagues in the profession, and fulfill his duties and obligations as a citizen of the
Republic of the Philippines.
Rule 3. The mechanical engineer shall update and enhance constantly his professional know
ledge and skills through assiduous research and study, and participation in continuing
professional development programs and seminars conducted or authorized by the Inte
grated Organization of Mechanical Engineers accredited by the Board of Mechanical
Engineering and the Professional Regulation Commission (PRC) or education institu
tions supervised by the State.
Rule 4. The ethical principles required to be observed by mechanical engineers shall equally
apply to partnership, firms and entities organized and exiting for the practice of
mechanical engineering.
Rule 5. The mechanical engineer shall honor and respect the supreme authority of the State the
Rule of Law, the primacy of the general welfare, the fundamentals rights of persons,
and the obligations and privileges of citizens recognized and guaranteed by the
Constitution of the Philippines.
Rule 6. He shall cooperate fully with the State in the pursuit of national development plans and
programs, shall respect the inviolability of national security, shall assist in the promotion
of peace and order and when circumstances arise shall assist in the prevention and/or
prosecution of unjust, criminal or unlawful acts and omissions.
Rule 7. He shall be ready to render the services needed for the development of the resources
of the country, and to offer his mechanical devices and inventions essential or
necessary for national defense.
Rule 8. In case of national emergency, he shall be ready to offer his professional knowledge,
skill and experience in the service of the State.
Rule 9. The mechanical engineer shall be well-informed of the latest technological progress in
his own line of work. He shall encourage or require whenever appropriate the use, or ap
plication of standard mechanical equipment, machinery, or process for safety, economy
and efficiency.
Rule 10. Whenever he designs a mechanical equipment, machinery or process, or prepares the
layout of a project, he must apply and adequate factor of safety, and provide for the ne
cessary leeway to insure and maintain for proper operating and maintenance condition.
Rule 11. When he discovers faulty or unsafe devices, equipment or machinery in any place, work or
plant, he shall without delay, give notice thereof to the proper authority, public of private,
for the immediate and effective correction, regardless of whether or not he is responsible
for said place, work or plant.
RELATIONS WITH LABOR
Rule 12. The mechanical engineer shall recognize labor as one of the major resources of our
country. He must acknowledge that a working man is not a mechanical robot but a
human being.
Rule 13. He should be familiar with State policies on labor and social justice, as well as,
the labor and social legislations and shall observe faithfully these policies and laws in
dealing with labor in general, and with his workmen in particular.
Rule 14. He shall strive to improve the skills of his workmen, pay them a fair living wage, and
instruct them on how to prevent accidents in their place of work.
Rule 15. The mechanical engineer shall observe punctuality in his appointments, perform
honestly and in good faith, his contractual obligation and his duties and obligations
to his clients or employer, and observe fair dealing i his relations with his clients and
employers.
Rule 16. He shall treat with confidentially any information obtained by him regarding the business
affairs and technical methods or processes of a client, or employer.
Rule 17. He shall inform his client or employer of his business connections, interests, or
affiliations which may influence his judgement, or impair the quality or character of his
services.
Rule 18. The mechanical engineer is entitled to a just and fair compensation of his services.
In the computation of such compensation, the period of time consumed, his
professional knowledge, skill, experience, and reputation, and the depreciation of
instruments and materials used, shall be considered and accorded such weight as is
just and reasonable.
Rule 19. He shall accept compensation, financial or otherwise, for his services from his clients
or employer only. He may agree to or receive compensation from any other source
,
only with the full knowledge and consent of all parties concerned.
Rule 20. The mechanical engineer shall be completely above suspicion or reproach in his
relation with his clients or employers, avoiding the remotest reference or relations to any
secret or questionable agreement on commissions or other financial consideration
promised by or received from any person or entity other than his client or employer.
Rule 21. “To thine ownself be true and thou cannot be false to any men” expresses the duty
which a mechanical engineer owes to himself and to others.
Rule 22. The mechanical engineer shall use only fair means to gain professional advancement.
In the pursuit thereof, he shall not injure the work or employment opportunities of others,
or use any improper or questionable method of soliciting employment or clients.
Rule 23. He shall refrain from associating with, or allowing the use of his name by, and any
person or entity of questionable reputation.
Rule 24. He shall provide the opportunity and the means to improve and advance the
knowledge, skills, and experience of his colleagues and associates.
Rule 25. He shall define clearly the line of authority and scope of responsibility of his associates
and assistance Orders, or the recall thereof, shall be issued through proper channels.
Rule 26. He shall be receptive to new ideas and suggestions from others, and ready to
recognize, encourage, and accredit the authors thereof. Suggestions for
colleagues and associates shall be given more careful attention.
Rule 27. He shall use tact and discretion in dealing with his colleagues and associates, but not
at the sacrifice of firmness. He shall work out difficult problems with courage and
serenity.
Rule 28. Careful selection of understudies shall be a guiding principle, and preference shall be
given to those with adequate engineering education.
Rule 29. He shall not expect others to face danger that he himself will not face. He shall
observe at all times safety requirements for the protection of all concerned.
Rule 30. The mechanical engineer shall actively support the duly accredited association with
the end in view of enhancing the practice of the profession and discharging his public
responsibilities as a professional.
PROVISIONS ON DISCIPLINARY ACTION
Rule 31. Violation of any provision of this Code shall constitute a ground for the revocation or
suspension of the certificate of registration and professional license I professional
identification card or the cancellation of a temporary or special permit under the
provisions of Sec. 26 and Sec. 27, Art Ill of R.A. No. 8495, known as the “Mechanical
Engineering Act of 1998” and Sec. 41, Rule VII of the “Rule and Regulations
Implementing R.A. No., 8495.
EFFECTIVITY
Rule 32. This Code shall take effect after fifteen (15) days following its publication in full in the
Official Gazette or in a newspaper of general circulation, whichever comes earlier.
/
ANTONIO RO. HERRERA
Chairman
DONIcTO K. KARAMIHAN CHONA . NGELISTA
Member e ber
Attested:
çACGLOR
Secretary, Professional Regulatory Boards
Approved:
Series of 2003
INC. (PSME) AS
RECOGNITION OF THE PHILIPPINE SOCIETY OF MECHANICAL ENGINEERS,
PROFESSIONAL MECHANICAL
THE ONE AND ONLY INTEGRATED AND ACCREDITED ORGANIZATION OF
ENGINEERS AND CERTIFIED PLANT MECHANICS.
“Philippine Mechanical
WHEREAS, Sec. 23,Art. Ill of RepublicAct. No.8495, otherwise known as the
Engineering Act of 1998”, provides:
organization of me
“Sec. 23 Integrated and Accreditation of mechanical Engineers. An Integrated
Mecha nical Engineering and
chanical engineers shall be created and accredited by the board of
the roll of profession
Professional Regulation Commission. All person whose names now appear in
under the custody
al mechanical engineers, mechanical engineers and certified plant mechanics
be includ ed therein upon registra
of the board and the Commission, or those who may hereafter
of the integra ted and
tion and payment of the required fees shall automatically become members
nical engineering
accredited organization of mechanical engineers. The integration of the mecha
ary organi zation of mecha nical engineers
professional shall not be a bar to the formation of volunt
nical engineers. The
which may coexist with the integrated and accredited organization of mecha
existing accredited
Board, subjected to the approval the commission and after consultation with the
nical engineers
organization of mechanical engineers and other affiliated organization of mecha
ers who are non-or ganization
and, if possible, with the substantial number of the mechanical engine
t and creatio n, con
members, shall provide the guidelines and mechanism for the establishmen
nical engineers. The
tinued supervision and the integrated and accredited organization of mecha
nics shall receive the benefits and
registered and licensed engineers and certified plant mecha
nical engineering
privileges appurtenant to their membership duly integrated and accredited mecha
association only upon payment of the required fees and dues.”
(2) to participate and or! support the Board and the Commission in planni
ng and
implementing programs and activities where such participation, suppor
t and
assistance are necessary for the accomplishment of the objectives, aims
and purposes of such programs and activities.
ANTOMORO.HERRERA
77 7 / Chairman
DONScTO K. KARAMIHAN ELISTA
Member ber
Attested:
gACg&GLMELOR
Secretary, Professional Regulatory Boards
Approved:
,,
AN ONIETA FORTUNA-IBE
j 7’) Chairperson
OFSO G. ABAD AVELINA DE LA REA-TAN
Commissioner Commissioner
3EkipuLiIic of tlw llji1ippInc
Jrofi.ionat 3&cçllkLtion Dornmtton
WHEREAS, Sec. 23 Art. Ill of Republic Act No. 8495, otherwise known as the “Philippines Mechanical
Engineering Act of 1998” requires that “[AjIl person whose names now appear in the roll of the professional mechanical
engineers, mechanical engineers and certified plant mechanics under the custody of the board and the
Commission, or those who may hereafter be included therein upon registration and payment of the required fees
shall automatically become members of the integrated and accredited organization of mechanical engineers”.
(Underscoring supplied)
WHEREAS, the President of the PSME has requested the Board of Mechanical Engineering to recommend
to the Commission to require the Professional Mechanical Engineers, Mechanical Engineers, Mechanical and Certified
Plant Mechanics who are not yet members of the PSME as of the date the PSME has been recognized as the one and
only integrated and accredited association of Professional Mechanical Engineers, Mechanical Engineers and
Certified Plant Mechanics to submit “Certificate of Good Standing” as members issued by the appropriate officials
of PSME as a condition for the issuance I renewal of their professional identification cards in order to hasten the
integration of all Professional Mechanical Engineers and Certified Plant Mechanics into
one and only recognized integrated and accredited association as required by Section 23 R.A. No. 8495,
afo re-quoted.
WHEREAS, the suggestion of the President of the PSME is well-taken as it will create a need for the
Professional Mechanical Engineers, Mechanical Engineers and Certified Plant Mechanics to register as members
of their professional organization.
WHEREFORE, the Board Resolved as it hereby Resolves to recommend to the Commssion to require
professional mechanical engineers, mechanical engineers and certified plant mechanics who are not yet members
of the PSME as of date of issuance of this Resolution to submit Certificates of Good Standing as member of the
PSME signed by its appropriate officials as a condition for the issuance I renewal of their professional
identification cards.
This Resolution shall take effect after Fifteen (15) days following its publication in the Officials Gazette or in a
newspaper of general circulation in the Philippines, whichever is earlier.
/
- ANTONIO RO. HERRERA
Chairman
DON TO K. KARAMIHAN CHONA .1 STA
Attested:
\ Member iber
c(9SGLMEWR
Secretary, Professional Regulatory Boards
_—. Approved:
.‘., 1-
ANT’ONIETA y
FORTUNA•lB,,<
Chairperson
O OGABAD AVELINA DE LA REA-TAN
Commissioner Commissioner
4,
i’puhlihn lul i1ipinns
REPUBLIC OF THE PHILIPPINES
nil luirI
PROFESSIONAL REGULATION COMMISSION
n1iimjnit ug mihnhi1n1n
CERTIFICATE OF ACCREDITATION
tIhngmi nit jPnglmhilntn JMg. —N)—Ut1
Certificate ofj4ccreditation [JV0. I-J4P0-005
nnn ng Lln1na
krutlwlmai lnbl
7 tit {ts’{nth1ihn Itiki. I.Ii ni 3nlns ncj cpitb{ihn {!itlit. L111 1 nI nil ntqn LLi.flthflrni n Althuthniin,
pertinent provisions of Rjpu6(ici4ct 0
qr 8495 andRepu6(ic4ct Wo. 8981 and its implementing cNu(es andR.pgu(ations,
nn tzmlnij nug anqtzrni ncr lulnnaLTml sn ffiuini1n Jthpnrnz nrrunnci thi— 1 nrrnu rai ..“sinsIn an kmiui _Ltltl
1
under the seal of this Commission at SManila cPlirlzppines this 1 day ofjaugust in the year 2008
/
LEONOR TRIPON-ROSERO
7 Secretary
RUTH RANA-PADILLA NILO L. ROSAS
hitnniijiitôtt i!OIlUSi1LUI.li1t1
Commissioner Commissioner
RESOLUTION NO.Z8-469
Series of 2008
I’or consideration of this Commission is the petition for the renewal of the
accreditation of Engr. Saylito M. Purisima in behalf of the Philippine Society of
Mechanical Engineers (PSME). as the bonaficle professional organization for
mechanical engineers. In support of its petition are the following, to wit:
i. Notarized pen ion signed by its President for the renewal of the
certificate of accreditation;
2. List of current officers including its chapters;
.
Photo copy of Certificate of Registration issued by the Securities and
Exchange Commission (SEC);
4. Photo copy of the Amended Articles of Incorporation and By-Laws;
5. Copy of audited financial statement submitted to the SEC duly signed
hr a Certified Public Accountant;
6. Complete list of members indicating their PRC Registration Nos. and
Dates o Registration;
7. Report on significaurt achievements as corporate body; and
8. Proof ot payment of t:he prescribed renewal fee.
RULE .
Renewal of Certthcatc of Accreditation.
-L
LEONOR TRIPON-ROSERO
Chairperson
T
Ai
NILO L. R SAS UT RANA ADILLA
Commissioner Commissioner
oc/oc/oc / D-STN
1;rrd/RRT’/NLR
ViJUL4,,
Republic Act No. 8495 (Philippine Mechanical Engineering Act of 1998), more
particularly Section 23 thereof, provides “xxx. AU persons whose names now appear
in the roll of professional mechanical engineeis, mechanical engineers and certified
plant mechanics under Ihe custody oF the Boaid and the Commission, or those who
may hereafter be included therein upon registration and payment of the required fees
shall automatically become members of the integrated and accredited organization
of mechanical engineers.”
In view of the foregoing, all concerned are hereby directed to strictly enforce the
provisions of Resolution No. 05, Series of 2003 and to coordinate with Philippine
Society of Mechanical Engineers (PSME), the accredited association of mechanical
engineers, presently headed by Engr. Vicente B. Vosotros for the implementation.
Let copies of the subject Resolution and opinion be furnished to all concerned for
their guidance.
. _
4
J4.
LEONOR TRIPON-ROSERO
Chairperson
PHILIPPINE SOCIETY OF MECHANICAL ENGINEERS
INTEGRATED ASSOCIATION OF MECHANICAL ENGINEERS
Accredited National Organization, Certificate I APO 005- -