Gas Burners for Forges Furnaces and kilns phần 1 ppsx

Building the 112-inch Burner Materials and tools lists Shopping for parts I .The burner nozzle 2.. Building the 314-inch Burner Materials and tools lists I .Assembling the burner n

for Forges Furnaces

Copyright O 2004 by Michael Porter

All rights reserved N o part of this publication may be repro- duced or transmitted in any form or by any means, electronic

or mechanical, including photocopy, recording, or any informa- tion storage and retrieval system without the written permis- sion of the publisher

Library of Congress Cataloging in Publication Data

Library of Congress Catalog Card Number

MIG Contact Tip Sizes For Burner Tube Diameters (chart) 22 Torch Welding Tips For Use as Gas Accelerators (chart) 23

3 Building the 112-inch Burner

Materials and tools lists

Shopping for parts

I The burner nozzle

2 Preparing the burner body

3 Making the basicchoke sleeve

4 Preparing the 112-inch t o 118-inch bell reducer

5 Installing the thumbscrew in the burner body

6 Laying out the air openings

7 Making the air openings

8 Placing the aiming screws

9 Making the temporary accelerator

I0.Assembling the valve and hose fittings

I I Building the permanent accelerator

I2.Tuning

13.Advanced burner options

14 Forging a flare on the choke sleeve

1 5 Advanced accelerator assembly

Materials and tools lists

16 Fabrication

Maintenance

4 Building the 314-inch Burner

Materials and tools lists

I Assembling the burner nozzle

2 Preparing the burner body

3.The flared choke sleeve

4 Preparing the 314-inch t o I M-inch bell reducer

5 Installing the thumbscrew

6 Laying out the air openings

7 Cutting the air openings

8 Placing the aiming screws

9 Making the gas accelerator assembly

I0.Assembling the valve and hose fittings

I I Testing and tuning

12 Maintenance

Tips for group projects

5 A Propane Bottle Gas Fired Forge

Forge design

Interior materials

Kiln shelving

The multiple burner forge

The Propane Bottle Forge

Materials and tools lists

I Acquiring the forge shell

2 Removing the protective carry-collar

3 Removing the cylinder valve

4 Laying out and cutting the first opening

5 Laying out and cutting the second opening

6 Cooking a used tank 72

7 Finishing the forge shell openings 72

9 Layout and installation of the burner collar 73

I I Installing the second lining 75

13 Making an opening for the burner 76

14 Cutting and placing the first end board 76

15 Coating the forge interior with ITC # I00 77

16 Cutting and placing the front ceramic fiberboard 78

18 Using the forge t o build exterior parts 80

Supplementary materials and tools lists 8 1

19 Making and attaching the burner collar 8 1

23 Single ball valve idler assembly 84 Proper procedure for safely starting and running the forge 86

6 Building a Forge Cart

Materials and tools lists

I Assembling the shelves

2 Constructing the legs

3 Mounting the legs, braces, and shelves

4 Installing the sheet metal side walls

5 Making and installing the top angles

6 Mounting the screens

7 Final wheel adjustments

8 Constructing the burner collar

9 Insulating the tabletop

I -inch Furnace Burner

Materials and tools lists

I Assembling the burner nozzle

2 Preparing the burner tube

3 Making the choke sleeve

4 Preparing the end cap and pressure nut

5 Installing the thumbscrew

6 Placing the aiming screws

7 Making the air openings

Optional sealing slots

Recommended ignition port

9 Making the gas accelerator assembly

I0.Assembling the valve and hose fittings Burner lgnition

Tuning

Maintenance

8 1 114-inch Furnace and Kiln Burner

Materials and Tools Lists

I Assembling the burner nozzle

2 Preparing the burner tube

3 Making the choke

4 Preparing the end cap

5 Installing the thumbscrew

6 Placing the aiming screws

7 Making the openings

8 Optional closing slots

9 Recommended ignition port

10 Making the gas accelerator assembly

I I Assembling the valve and hose fittings Burner lgnition

Tuning

9 Foundry Furnaces

Building the jeweler's furnace

Materials and Tools Lists

I Laying out the tank ends

2 Cutting the exhaust opening

3 Drilling out the opening for the burner collar

4 Preparing the tank

5 Cutting the the tank in two

6 Constructing and mounting the burner collar

7.Attaching the legs

8 Mounting the handle and attaching the lid

9 lnstalling the self drilling screws

10 Building a plinth

I I Lining the furnace

12 Heat curing

13 Finishing the shape of the exhaust port

14.Applying finish coatings

Fastener Assembled Version

Constructing the burner collar

Mounting the handle and attaching the lid

Running the furnace

10 Farrier's Forge

Materials and tools lists

I Making the forge shell

2 Constructing the burner collar

3 Mounting the legs

4 Mounting the lid and installing a handle

5 lnstalling the insulation and the bottom shelf

6 lnstalling the insulation and heat shield

7 Curing and coating the forge

Maintenance

I I Multi-hole Glass Furnace

Materials and tools lists

Fabrication

I Making the furnace plug

2 Laying out the tank

3 Making and attaching the two furnace sections

4 Constructing the locks

5.Attaching the axles

6 Building the carriage frame

7 Installing the axle slots

8 Building the carriage back

9 Installing the top panels and bellyband

10 Constructing and mounting the burner collar and plate

I I Mounting front panels

12 Mounting side panels

13 Mounting the back panel and cover plate 15 1

14 Making the furnace plug and installing the refractory 15 1 I5.Additional cart with sliding bottom door 15 1

12 Brazing

Brazing and soldering

Silver brazing basics

What filler rod t o choose

Make a practice run first

Chapter Notes

Glossary

Resources

Index

Construction plans for the forges, furnaces, and burners in this book are laid out in step by step detail with drawings explaining the steps of con- struction There are also alternate choices to make your work as convenient

as possible Drawings, photographs, and a list of sources are also provided The burners are designed for construction from readily available plumbing parts with the most exotic component being a contact tip that can be purchased at any welding supply store The forge bodies are made from containers, and they're insulated with materials available from pottery suppliers or by mail order

Publisher's Note

This book is loaded with information and can be overwhelming if it is taken in one reading So focus on what is your major interest and begin there Since I am a blacksmith, I was interested in making a forge I started with the 112-inch burner and found out that it really works well It also got

me over the hangup of using and working with propane Then I built the 314-inch burner and had a blast when I installed in the propane bottle forge This is now in my garage on a purchased cart What a relief to find that I can fire up and shut down quickly and not make a smelly mess, much

to the delight of my wife and neighbors

I also found out that it was easier to find information when I put Post-

it strips at the chapter heads and at special places to return to for critical instruction or parts lists

The Furnace Town Blacksmithing Guild, that I am a member of, is located at the site of an early American, 1827 to 1850, iron furnace Our next major project will be developing a foundry at this site for demonstra- tions We will be using the foundry furnace that Mike has designed and described in this book

Safety

There is no need to feel uneasy about using gas forges if proper safety precautions are taken You already possess the most important piece of safety equipment-your mind Safety begins by informing yourself about every pertinent aspect of an endeav-

or and then using the information acquired by others to avoid learning your own les- sons the hard way Safety is established when you build a complete and accurate men- tal picture of what procedures are prudent, and it grows as you deliberately follow those procedures at all times until they become habit Safety, however, ends when you decide to depart from approved practice, usually for convenience sake

To start, learn about propane, the tools, and materials used to build a burner for

a forge, furnace, or kiln and follow the manufacturer's recommendations If you are not sure how to properly use propane or a tool, stop-ask someone who knows

If you live in an area with hard winters and must work the forge inside during bad weather, set up an exhaust hood and open the shop door or window slightly The forge puts out plenty of heat to overcome any draft this might cause When running

a forge indoors, your local safety codes may even require that you use a specific kind

of venting system-you will need to familiarize yourself with those codes

After assembling gas equipment, check it for leaks beginning with the valve on the fuel tank, then the fittings, regulator, hoses, and burner valves using soapy water while the system is pressurized Anytime you smell gas, check everything again and fur any leaks immediately.'

When starting one of these burners, it is usually necessary to partially close the choke until the burner nozzle warms up Also, it is most important to make sure the choke is not completely closed or the burner will create a large yellow flame with a very large heat zone, endangering you and your work area

These are naturally aspirated burners designed to generate the most heat possi- ble In doing so, they use more air than previous designs If these burners are posi-

Gas Burners I

tioned facing straight down without sealing the forge penetration, spent gasses will rise past the air intake on the burner This will seriously interfere with the burner's ability to draw in the needed fresh air to function

When using these burners for brazing, keep them positioned at less than a verti- cal angle If you see the burner flame start to hesitate or hear the burner "huff," sim- ply decrease the angle you're holding

To use fuel cylinders, open their valves completely Most modern tanks have dou- ble seat valves that are meant to seal completely in both the fully open and fully closed positions When a valve is partially open only the valve's packing seals it A

habit that older workers have of only opening the fuel valve a one-quarter turn stems from the days before flashback arrestors were installed on oxylfuel systems It was necessary then to be able to instantly close the valve if a workman heard the sound

of oxygen burning its way back along the fuel hose toward the acetylene tank; how- ever, it is inappropriate today

There is much confusion between airlfuel burners and oxylfuel systems With an oxygen fed torch there is a possibility of flashback This happens when oxygen infil- trates the fuel hose through a torch In an airlfuel system there is no pressurized oxy- gen source, and the danger of flashback does not apply No flashback arrestors are needed

Use approved propane tanks only Your dealer might fill them illegally for you, but that will not make them safe Also, place propane tanks in positions for which they were designed These tanks have internal safety devices, which are defeated if they are used out of position Every propane cylinder comes equipped with a built-

in spring-loaded pressure relief valve If internal pressure increases within the tank to dangerous levels, which can easily happen on a hot day, the relief valve is momentar- ily forced open This results in a small amount of gas escaping, which allows the pres- sure to fall back within safe limits If the cylinder is sitting on its side, this valve is likely to be positioned below the level of the liquid, instead of in the vapor area above

it Should the valve open in this position, liquid propane will escape instead of vapor The liquid will then immediately expand to about 270 times its pressurized volume, multiplying the risk of ignition!

Proper safety procedure requires keeping the propane tank in a well-ventilated and protected area completely separated from hot work Use black wall pipe to run the gas from the external tank into the work areas where the gas is likely to be used

Do not use or store even a small cylinder in a building, garage or enclosed area, rather leave the tank outside running an approved hose to the work until you can build pip- ing Put the cap over the valve outlet when not in use to protect its parts from dirt

"T" fittings with valves and gas rated connectors allow fuel hose to be run a short distance from piping to the work sites The connector will not allow gas to flow when nothing is coupled to it, so it becomes an additional safety device if the cylinder valve

is left open by mistake A ball valve allows the connection to be serviced without draining the piping system and serves as insurance against leaks

Take care not to let the fuel hose become a fire danger or a tripping hazard Use hooks in the ceiling to hold the hose well out of the way Also use gas rated quick

Safety

liquid

Fig 1-1 The upright cylinder on the left shows the liquid propane lying safely below the vapor space Only vapor will be drawn off in that position The cylinder on its side on the right shows the main filler valve, with its built in pressure relief valve, below the level of the liquid propane

In this position liquid will be drawn off instead of vapor

release couplings

A portable forge and a small tank can be set up in a cart permitting the tank to

be easily removed and kept at a safe distance during hot work (See Chapter 6,

"Building a Forge Cart.") The cart is also useful for transport between job sites Never transport or store the tank in the vehicle's passenger area or in a closed trunk Make sure the container is secured in an upright position before transport Do not allow the tank to be exposed to high temperatures as this could force the relief valve to open and discharge propane

Never attempt to use a barbecue regulator or an oxygen regulator with fuel

gasses Use only regulators that are rated for the particular fuel gas you are using A

word of caution about acetylene regulators-the red zone above fifteen PSI is appli- cable only to acetylene, but you must make sure that the regulator will accommodate propane; better brands, but not all new acetylene regulators will, most old acetylene regulators will not accommodate propane

Use only approved hoses, valves, and fittings This includes the fittings for cop- per tubing if you decide to "plumb" your forge connections Do not use tubing on the high-pressure side of a regulator, and use a gas-approved sealant on all pipe thread

Procedures for safely starting, running, and shutting down the forge or furnace are given at the end of the forge-building chapter Learn the safety codes in your area

as they apply to fuel gas equipment and comply with them They are meant for your