Steam was provided by two Lancashire boilers 9.2 metres by 2.4 metres in diameter. Water was preheated by an economiser.
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The economiser is a crucial component for efficient performance of a thermal power plant. It is a non-steaming type of heat exchanger which is placed in the convective zone of the furnace. It takes the heat energy of the flue gases for heating the feed water before it enters the boiler drum. The thermal efficiency/boiler efficiency largely depends on the performance of the economiser.
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The HP cylinders had Corliss valves; they were steamed at 120psi, by four Lancashire boilers, An economiser was used. Marine type connecting rods and trunk guides were fitted.
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Evidence remains in the concrete floor of boiler and ash pits. Both the boiler house and economiser house are in poor condition. Directly east and adjoining the boiler house is the original 1921 engine house which is of the same construction overall as the boiler house and economiser house. The existing pumps and engines in the engine house date from the mid to late 20th century following the electrification of the pumping station.
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CFD analysis helps in optimizing the thermal performance of the economiser by analysing the pressure, velocity and temperature distribution, and to identify the critical areas for further improvement with the result obtained by CFD analysis.
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One such preserved site is the Claymills Pumping Engines Trust in Staffordshire, England, which is in the process of restoring one set of economisers and the associated steam engine which drove them. Another such example is the British Engineerium in Brighton & Hove, where the economiser associated with the boilers for Number 2 Engine is in use, complete with its associated small stationary engine. A third site is Coldharbour Mill Working Wool Museum, where the Green's economiser is in working order, complete with the drive shafts from the Pollit and Wigzell steam engine.
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Sir Edward Green, 1st Baronet (4 March 1831 – 30 March 1923) was an English ironmaster and a Conservative politician who sat in the House of Commons between 1885 and 1892. Green was the son of Edward Green (engineer), a Yorkshire ironmaster who founded E. Green & Son based in Wakefield and patented "Green's Economiser". This was a device for recycling heat from boilers that previously went to waste.William Henry Fowler Fifty Years' History of the Development of Green's Economiser Green was educated at West Riding Proprietary School and in Germany, and became an engineer in his father's business.
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From there the water is lifted further by ram pumps. Both the lift and ram pumps are powered by two horizontal tandem compound Corliss valve engines using steam raised by three Lancashire boilers. The efficiency of steam-raising is increased by a Green's economiser.
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Koss, 73 The Cabinet was therefore divided with 'economiser' Lloyd George joined alongside by fundamental Gladstonians such as Lord Bryce, Marquess of Ripon, Viscount Hawarden, and the whigs, Earl of Elgin, Lord Carrington and Crewe. The Imperialists were bolstered by Buxton, Fowler, Marquess of Tweedmouth, Birrell, and J. Sinclair.
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Heat transfer from hot gases to water and steam The steam power plant gets its input heat from the high temperature exhaust gases from gas turbine power plant. The steam generated thus can be used to drive steam turbine. The Waste Heat Recovery Boiler (WHRB) has 3 sections: Economiser, evaporator and superheater.
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The pumping station building which fronts Victoria Road comprises a small Administration Block, the Engine House and the adjoining Boiler House and Economiser House. There is also a reinforced concrete viaduct or coal staith at the south end, which allowed railway coal wagons to be transported to the top of the building and emptied over the coal bunkers inside. Under the Engine and Boiler Houses there are basements and a sub-basement is located under the Engine Room which houses the turbine condensers and auxiliary pumps. The Boiler House occupies the central section of the Pumping Station and is much higher than the flanking Engines and Economiser Houses, the cladding on the main roof and the monitor is the original fibro tiles.
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Ericsson coined the term "regenerator" for his independent invention of the mixed-flow counter-current heat exchanger. However, Rev. Robert Stirling had invented the same device, prior to Ericsson, so the invention is credited to Stirling. Stirling called it an "economiser" or "economizer", because it increased the fuel economy of various types of heat processes.
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The engines were fitted with Corliss valves operated by a simple proprietary trip motion. The piston rods for the HP and IP are and . During the test, the two by Lancashire boilers with 3 ft 2 in diameter flues produced steam at 156 psi. There were Galloway tubes in the flues and behind the boilers was an economiser with 288 pipes.
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Steam was raised by a Lancashire boiler and in 1947, when the warehouse needed extra steam for sizing, a Cornish boiler was added but disconnected in 1948 because of problems sharing the same flue. A Green's economiser preheated the feedwater. The boiler was stoked manually, until a Proctor automatic stoker was fitted in the 1930s. Steam was raised to 160 psi.
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Before the feedwater was introduced to the boiler it was heated up in stages. There were seven feedwater heaters on each unit which gradually increased the pressure and temperature of the water, until it reached a final feed temperature of around 210 °C. A steam driven Main Boiler Feed Pump (MBFP) pumped the water through the boiler Economiser and into the boiler Drum.
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This was a prominent change as a rope race had to be built running the height of the mill. The engine needed more space and the engine house, boiler house and economiser were external to the main mill. Mills continued to get bigger, and were sometimes paired; two mills being driven by one engine. Another change was the trend of having carding on one floor.
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Above the tube banks a single flat spiral tube was used as an economiser or feedwater heater. The furnace used to fire these large boilers was annular, often with four or more separate firedoors. The boiler was also successfully fired with bagasse, plant waste or refuse. Where they were used for continual high-power production, such as for electricity generation, some were also used with early automatic stokers.
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The heat recovery boiler is item 5 in the COGAS figure shown above. Hot gas turbine exhaust enters the super heater, then passes through the evaporator and finally through the economiser section as it flows out from the boiler. Feed water comes in through the economizer and then exits after having attained saturation temperature in the water or steam circuit. Finally it flows through the evaporator and super heater.
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The Boiler House still contains its rail lines and coal bunkers at roof level, but the boilers have been removed. The Economiser House is on the west side of the building adjoining the Boiler House but much lower. Its roof structure, cladding and length is the same as the Boiler House. Although it is now empty it originally contained the economisers, induced draught fans and the feed pumps and feed water heater for the boilers.
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The overall construction of the pumping station comprises a brick walled and steel framed interior economiser house with extant bases of the original reinforced concrete chimneys. Timber louvres remain to the original monitor roof. Arched headed windows are in steel and only a few original steel windows remain in the front office areas. Mid to late 20th century security bars have been fitted to the windows and verandah enclosure to the office.
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The 1877 Stott mill was powered by a pair of 700 hp W & J Galloway & Sons compound engine with a pair of 500 hp condensing beam engines using a Green's Economiser on each. In 1835, they had calculated that they needed 32 hp to drive their 320 looms, 25 hp to drive their 6400 throstle spindles and 17 hp to drive their 8640 mule spindles – 74 hp in all. In 1841 they doubled the capacity of the mill and bought an extra two 40 hp engines.
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Cockenzie Power Station A boiler drum made with Ducol plates, manufactured by Babcock & Wilcox Ltd (now Doosan Babcock) at Renfrew, near Glasgow, to BS 1113 (1958) was installed at Cockenzie Power Station in East Lothian, Scotland. It exploded on 6th May 1967 under repeated pressure testing. According to Jim Thomson, the failure was caused by a crack (created during the original manufacturing process) which occurred next to an economiser nozzle replaced during testing; the crack had penetrated part-way through the thick wall of the pressure vessel.
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This action held the protecting signal at red as a safety measure, so in order to clear it, he obtained a false feed between two of the economiser contacts, most likely using a Bardic lamp or a broken hinge that was subsequently found. It was likely that he then accidentally inched the points slide too far, and they moved under the train. False-feeding was apparently common knowledge between signalmen in the 10 similar signal boxes in the area, and the frames were subsequently boxed in.
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From here it was fed into a boiler in powder form and burned. All of the boilers were suspended from the boiler houses' steel frames, and were made by Clarke Chapman Group Ltd, Gateshead. The boilers were forged in Sheffield, the first of the nine arriving at Stella South in 1953. At 62 tonnes, the boilers were at the time the largest ever made in the UK. The boilers were of the radiant-heat type, comprising a water- cooled combustion chamber, controlled-type superheater and an economiser.
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Godward set up his own cycle business in 1908 and after a short time began importing Reo motor cars. He turned his attention to improving these and developed a carburettor in 1912 called the Eclipse Petrol Economiser. In 1913 he took his invention to London where he established the Godward Carburettor Company at Kingston upon Thames and patented the device in 1914. This venture proved less successful than he had hoped, so in 1916 Godward opened an office in New York, basing himself there.
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Robert Stirling's innovative contribution to the design of hot air engines of 1816 was what he called the 'Economiser'. Now known as the regenerator, it stored heat from the hot portion of the engine as the air passed to the cold side, and released heat to the cooled air as it returned to the hot side. This innovation improved the efficiency of Stirling engine enough to make it commercially successful in particular applications, and has since been a component of every air engine that is called a Stirling engine.
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Frank Green's grandfather Edward Green had invented, and patented in 1845, a fuel economiser which was very successful during the 19th and 20th centuries and which made the family fortune. Green was educated at Eton College and then the University of Oxford but he did not graduate. Frank displayed a volatile temper from early on, once for example, striking a tutor with a cricket bat. Whilst his brother's role was to raise the family's social position, Frank assisted his father in the management of the company that had factories in various countries.
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Introducing cold water into a boiler reduces power, and from the 1920s a variety of heaters were incorporated. The most common type for locomotives was the exhaust steam feedwater heater that piped some of the exhaust through small tanks mounted on top of the boiler or smokebox or into the tender tank; the warm water then had to be delivered to the boiler by a small auxiliary steam pump. The rare economiser type differed in that it extracted residual heat from the exhaust gases. An example of this is the pre-heater drum(s) found on the Franco-Crosti boiler.
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In this capacity he introduced the First Voluntary Disclosure Scheme, known as the Tyagi Scheme, primarily, as he put it, to bring into the open incomes which had not been revealed to the alien government prior to independence. While in the Ministry of Finance, Tyagi earned a reputation as a strict economiser. His practical, man-of-the-soil approach was reflected also at the first meeting of the National Development Council, held in Delhi on 8 and 9 November 1952, where Tyagi suggested that "manual work should be made part of the daily curriculum of education".
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The external cladding of the upper most monitor roof is corrugated steel and the guttering has been replaced in colorbond. Some windows to the offices have been changed from their original steel to timber and aluminium in the late 20th century. A reasonable amount of the interior finishes and joinery in the offices remains intact, although the economiser house has been stripped and disused. On the upper reaches of the boiler house are the original coal bunkers which were fed from the existing reinforced concrete coal staith which heads in a southern direction from the upper reaches of the boiler house.
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Sir William Jackson was now the owner of Clay Cross Company and in 1866 he appointed his son John Jackson (1843–1899) to run the Clay Cross Coal and Iron Works. By 1871 Sir William had bought out all of the company's interests and he became the sole proprietor. The Clay Cross Economiser Company was set up to manufacture fuel economisers, which used the waste heat from steam boilers to improve their efficiency. Sir WIlliam turned the Clay Cross Company into a limited company in 1913, consisting of seven collieries (producing "CXC Gold Medal" coal), a brickworks, a gas plant, a limestone quarry, three blast furnaces and an iron foundry.
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This produces saturated steam at a rate which can vary according to the pressure above the boiling water. The higher the furnace temperature, the faster the steam production. The saturated steam thus produced can then either be used immediately to produce power via a turbine and alternator, or else may be further superheated to a higher temperature; this notably reduces suspended water content making a given volume of steam produce more work and creates a greater temperature gradient, which helps reduce the potential to form condensation. Any remaining heat in the combustion gases can then either be evacuated or made to pass through an economiser, the role of which is to warm the feed water before it reaches the boiler.
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Adjoining the Mobbs Hill extension to the south again is a mid to late 20th century workshop building constructed of brick walls, gable roof with sheet metal roof cladding and roof lights. A separate building to the south of the economiser house is an original brick with flat roof former paint shop, the exterior of which is considerably intact but in poor condition. To the east of the former paint shop is a reinforced concrete neumatic ash tank which appears to be considerably intact but in poor condition. Some 10 metres to the south of the Hermitage Road entrance to the site is located a single storey brick and concrete roofed pump and valve house dating from the early to mid 20th century.
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The Lancashire boiler was patented in 1844, and the economiser in 1845. This can be seen as a square brick structure between the boiler house and the chimney. The engines were double compound upright beam engines of the type patented by McNaught in 1845. Each room in the mill would have line shafts suitable for the type of frame, connected by belt drives or gearing. In 1860, there were 2650 cotton mills in the Lancashire region, employing 440,000 people. The workers, 90 per cent of whom were adults and 56 per cent females, were paid a total of £11.5 million per annum. The mills used 300,000 hp of power, of which 18,500 was generated by waterpower. The mills had 30,387,467 spindles and 350,000 power looms. The industry imported 1,390,938,752 lb of raw cotton a year.
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After fulfilling its role of powering the turbine’s wheels, the steam was directed to the condensers where it returned to its liquid state, allowing that water to be reused in the boilers. The steam entered the condenser and, through contact with the tubular system which was filled with cold water, turned back into its liquid state. This cooling water was harvested from the Tagus River through three ingoing pipelines and one outgoing pipeline that forced the water into the channels through a siphoning effect. The river water never mixed with the pure water used in the boilers, since, as has already been mentioned, the Tejo’s water circulated in a tubular system inside the condensers, while the steam travelled in free space. The water resulting from this condensation of steam was suctioned by the extraction pumps and sent once again to the boilers’ steam drums, passing first through the water heaters, feed tanks and pumps, and finally to the economiser.
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The boiler is fundamentally made up of 3 circuits: water/steam, air/smoke and boiler dust (ash). Each circuit’s function is indispensable and complementary to the others. The water/steam circuit’s function was to transform the liquid water into steam; the air/smoke circuit was of great importance, since the better or worse use of the circuit was reflected in the variation in the boiler’s output; and finally, the ash circuit, from where unburned coal and ash resulting from the boiler’s combustion were recovered. The water necessary to produce steam was treated and circulated in a closed circuit, entering the boiler through the economiser located at the top, and from here passed on to the steam drum located on top of the boiler, which functioned as a water and steam reservoir, serving as a connection between the two circuits. From the steam drum, water came down the “Bailey walls”, in other words, the walls located on the inside of the boiler's furnace, designed to hold the heat inside and built in cast iron with numerous vertical tubes along which the water circulated while it vaporised.
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