Injector

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Injector used in steam locomotives Boiler Feed Injector Diagram.svg
Injector used in steam locomotives
A- Steam from boiler, B- Needle valve, C- Needle valve handle, D- Steam and water combine, E- Water feed, F- Combining cone, G- Delivery nozzle and cone, H- delivery chamber and pipe, K- Check valve, L- Overflow Injector Giffard-02.jpg
A- Steam from boiler, B- Needle valve, C- Needle valve handle, D- Steam and water combine, E- Water feed, F- Combining cone, G- Delivery nozzle and cone, H- delivery chamber and pipe, K- Check valve, L- Overflow

An injector is a system of ducting and nozzles used to direct the flow of a high-pressure fluid in such a way that a lower pressure fluid is entrained in the jet and carried through a duct to a region of higher pressure. It is a fluid-dynamic pump with no moving parts except a valve to control inlet flow.

Contents

Depending on the application, an injector can also take the form of an eductor-jet pump, a water eductor or an aspirator. An ejector operates on similar principles to create a vacuum feed connection for braking systems etc.

The motive fluid may be a liquid, steam or any other gas. The entrained suction fluid may be a gas, a liquid, a slurry, or a dust-laden gas stream. [1] [2] [3]

Steam injector

The steam injector is a common device used for delivering water to steam boilers, especially in steam locomotives. It is a typical application of the injector principle used to deliver cold water to a boiler against its own pressure, using its own live or exhaust steam, replacing any mechanical pump. When first developed, its operation was intriguing because it seemed paradoxical, almost like perpetual motion, but it was later explained using thermodynamics. [4] Other types of injector may use other pressurised motive fluids such as air.

History

Giffard

The injector was invented by Henri Giffard in early 1850s and patented in France in 1858, for use on steam locomotives. [5] It was patented in the United Kingdom by Sharp, Stewart and Company of Glasgow.

After some initial scepticism resulting from the unfamiliar and superficially paradoxical mode of operation, [6] :5 the injector became widely adopted for steam locomotives as an alternative to mechanical pumps. [6] :5,7

Kneass

Strickland Landis Kneass was a civil engineer, experimenter, and author, with many accomplishments involving railroading. [7] Kneass began publishing a mathematical model of the physics of the injector, which he had verified by experimenting with steam. A steam injector has three primary sections: [6]

Nozzle

Kneass's illustrations of differently shaped steam nozzles Kneass15steamDischarge.png
Kneass's illustrations of differently shaped steam nozzles

Figure 15 shows four sketches Kneass drew of steam passing through a nozzle. In general, compressible flows through a diverging duct increases velocity as a gas expands. The two sketches at the bottom of figure 15 are both diverging, but the bottom one is slightly curved, and produced the highest velocity flow parallel to the axis. The area of a duct is proportional to the square of the diameter, and the curvature allows the steam to expand more linearly as it passes through the duct.

An ideal gas cools during adiabatic expansion (without adding heat), releasing less energy than the same gas would during isothermal expansion (constant temperature). Expansion of steam follows an intermediate thermodynamic process called the Rankine cycle. Steam does more work than an ideal gas, because steam remains hot during expansion.

The extra heat comes from enthalpy of vaporization, as some of the steam condenses back into dropplets of water intermixed with steam. [6]

Combining tube

At the end of the nozzle, the steam has very high velocity, but at less than atmospheric pressure, drawing in cold water which becomes entrained in the stream, where the steam condenses into droplets of water in a converging duct.

Delivery tube

The delivery tube is a diverging duct where the force of deceleration increases pressure, allowing the stream of water to enter the boiler.

Operation

The injector consists of a body filled with a secondary fluid, into which a motive fluid is injected. The motive fluid induces the secondary fluid to move. Injectors exist in many variations, and can have several stages, each repeating the same basic operating principle, to increase their overall effect.

It uses the Venturi effect of a converging-diverging nozzle on a steam jet to convert the pressure energy of the steam to velocity energy, reducing its pressure to below that of the atmosphere, which enables it to entrain a fluid (e.g., water). After passing through the convergent "combining cone", the mixed fluid is fully condensed, releasing the latent heat of evaporation of the steam which imparts extra velocity to the water[ how? ]. The condensate mixture then enters a divergent "delivery cone" which slows the jet, converting kinetic energy back into static pressure energy above the pressure of the boiler enabling its feed through a non-return valve. [8] [9]

Most of the heat energy in the condensed steam is returned to the boiler, increasing the thermal efficiency of the process. Injectors are therefore typically over 98% energy-efficient overall; they are also simple compared to the many moving parts in a feed pump.

Steam injector of a locomotive boiler Injektor Dampfstrahlpumpe.jpg
Steam injector of a locomotive boiler

Key design parameters

Fluid feed rate and operating pressure range are the key parameters of an injector, and vacuum pressure and evacuation rate are the key parameters for an ejector.

Compression ratio and the entrainment ratio may also be defined:

The compression ratio of the injector, , is defined as ratio of the injector's outlet pressure to the inlet pressure of the suction fluid .

The entrainment ratio of the injector, , is defined as the amount (in kg/h) of suction fluid that can be entrained and compressed by a given amount (in kg/h) of motive fluid.

Lifting properties

Other key properties of an injector include the fluid inlet pressure requirements i.e. whether it is lifting or non-lifting.

In a non-lifting injector, positive inlet fluid pressure is needed e.g. the cold water input is fed by gravity.

The steam-cone minimal orifice diameter is kept larger than the combining cone minimal diameter. [10] The non-lifting Nathan 4000 injector used on the Southern Pacific 4294 could push 12,000 US gallons (45,000 L) per hour at 250 psi (17 bar). [11]

The lifting injector can operate with negative inlet fluid pressure i.e. fluid lying below the level of the injector. It differs from the non-lifting type mainly in the relative dimensions of the nozzles. [12]

Overflow

An overflow is required for excess steam or water to discharge, especially during starting. If the injector cannot initially overcome boiler pressure, the overflow allows the injector to continue to draw water and steam.

Check valve

There is at least one check valve (called a "clack valve" in locomotives because of the distinctive noise it makes [9] ) between the exit of the injector and the boiler to prevent back flow, and usually a valve to prevent air being sucked in at the overflow.

Exhaust steam injector

Efficiency was further improved by the development of a multi-stage injector which is powered not by live steam from the boiler but by exhaust steam from the cylinders, thereby making use of the residual energy in the exhaust steam which would otherwise go to waste. However, an exhaust injector also cannot work when the locomotive is stationary; later exhaust injectors could use a supply of live steam if no exhaust steam was available.

Problems

Injectors can be troublesome under certain running conditions, such as when vibration causes the combined steam and water jet to "knock off". Originally the injector had to be restarted by careful manipulation of the steam and water controls, and the distraction caused by a malfunctioning injector was largely responsible for the 1913 Ais Gill rail accident. Later injectors were designed to automatically restart on sensing the collapse in vacuum from the steam jet, for example with a spring-loaded delivery cone.

Another common problem occurs when the incoming water is too warm and is less effective at condensing the steam in the combining cone. That can also occur if the metal body of the injector is too hot, e.g. from prolonged use.

The internal parts of an injector are subject to erosive wear, particularly damage at the throat of the delivery cone which may be due to cavitation. [13]

Vacuum ejectors

Diagram of a typical modern ejector Ejector or Injector.svg
Diagram of a typical modern ejector

An additional use for the injector technology is in vacuum ejectors in continuous train braking systems, which were made compulsory in the UK by the Regulation of Railways Act 1889. A vacuum ejector uses steam pressure to draw air out of the vacuum pipe and reservoirs of continuous train brake. Steam locomotives, with a ready source of steam, found ejector technology ideal with its rugged simplicity and lack of moving parts. A steam locomotive usually has two ejectors: a large ejector for releasing the brakes when stationary and a small ejector for maintaining the vacuum against leaks. The exhaust from the ejectors is invariably directed to the smokebox, by which means it assists the blower in draughting the fire. The small ejector is sometimes replaced by a reciprocating pump driven from the crosshead because this is more economical of steam and is only required to operate when the train is moving.

Vacuum brakes have been superseded by air brakes in modern trains, which allow the use of smaller brake cylinders and/or higher braking force due to the greater difference from atmospheric pressure.

Earlier application of the principle

Sketch of the smokebox of a steam locomotive, rotated 90 degrees. The similarity to the generic injector diagram at the top of this article is apparent. Smokebox ejection mechanism.png
Sketch of the smokebox of a steam locomotive, rotated 90 degrees. The similarity to the generic injector diagram at the top of this article is apparent.

An empirical application of the principle was in widespread use on steam locomotives before its formal development as the injector, in the form of the arrangement of the blastpipe and chimney in the locomotive smokebox. The sketch on the right shows a cross section through a smokebox, rotated 90 degrees; it can be seen that the same components are present, albeit differently named, as in the generic diagram of an injector at the top of the article. Exhaust steam from the cylinders is directed through a nozzle on the end of the blastpipe, to reduce pressure inside the smokebox by entraining the flue gases from the boiler which are then ejected via the chimney. The effect is to increase the draught on the fire to a degree proportional to the rate of steam consumption, so that as more steam is used, more heat is generated from the fire and steam production is also increased. The effect was first noted by Richard Trevithick and subsequently developed empirically by the early locomotive engineers; Stephenson's Rocket made use of it, and this constitutes much of the reason for its notably improved performance in comparison with contemporary machines.

Modern uses

The use of injectors (or ejectors) in various industrial applications has become quite common due to their relative simplicity and adaptability. For example:

Well pumps

Jet pumps are commonly used to extract water from water wells. The main pump, often a centrifugal pump, is powered and installed at ground level. Its discharge is split, with the greater part of the flow leaving the system, while a portion of the flow is returned to the jet pump installed below ground in the well. This recirculated part of the pumped fluid is used to power the jet. At the jet pump, the high-energy, low-mass returned flow drives more fluid from the well, becoming a low-energy, high-mass flow which is then piped to the inlet of the main pump.

The S type pump is useful for removing water from a well or container. S Eductor pump.svg
The S type pump is useful for removing water from a well or container.

Shallow well pumps are those in which the jet assembly is attached directly to the main pump and are limited to a depth of approximately 5-8m to prevent cavitation.

Deep well pumps are those in which the jet is located at the bottom of the well. The maximum depth for deep well pumps is determined by the inside diameter of and the velocity through the jet. The major advantage of jet pumps for deep well installations is the ability to situate all mechanical parts (e.g., electric/petrol motor, rotating impellers) at the ground surface for easy maintenance. The advent of the electrical submersible pump has partly replaced the need for jet type well pumps, except for driven point wells or surface water intakes.

Multi-stage steam vacuum ejectors

In practice, for suction pressure below 100 mbar absolute, more than one ejector is used, usually with condensers between the ejector stages. Condensing of motive steam greatly improves ejector set efficiency; both barometric and shell-and-tube surface condensers are used.

In operation a two-stage system consists of a primary high-vacuum (HV) ejector and a secondary low-vacuum (LV) ejector. Initially the LV ejector is operated to pull vacuum down from the starting pressure to an intermediate pressure. Once this pressure is reached, the HV ejector is then operated in conjunction with the LV ejector to finally pull vacuum to the required pressure.

In operation a three-stage system consists of a primary booster, a secondary high-vacuum (HV) ejector, and a tertiary low-vacuum (LV) ejector. As per the two-stage system, initially the LV ejector is operated to pull vacuum down from the starting pressure to an intermediate pressure. Once this pressure is reached, the HV ejector is then operated in conjunction with the LV ejector to pull vacuum to the lower intermediate pressure. Finally the booster is operated (in conjunction with the HV & LV ejectors) to pull vacuum to the required pressure.

Construction materials

Injectors or ejectors are made of carbon steel, stainless steel, brass, titanium, PTFE, carbon, and other materials.

See also

Related Research Articles

<span class="mw-page-title-main">Diffusion pump</span> High vacuum pump

Diffusion pumps use a high speed jet of vapor to direct gas molecules in the pump throat down into the bottom of the pump and out the exhaust. They were the first type of high vacuum pumps operating in the regime of free molecular flow, where the movement of the gas molecules can be better understood as diffusion than by conventional fluid dynamics. Invented in 1915 by Wolfgang Gaede, he named it a diffusion pump since his design was based on the finding that gas cannot diffuse against the vapor stream, but will be carried with it to the exhaust. However, the principle of operation might be more precisely described as gas-jet pump, since diffusion also plays a role in other types of high vacuum pumps. In modern textbooks, the diffusion pump is categorized as a momentum transfer pump.

<span class="mw-page-title-main">Steam engine</span> Engine that uses steam to perform mechanical work

A steam engine is a heat engine that performs mechanical work using steam as its working fluid. The steam engine uses the force produced by steam pressure to push a piston back and forth inside a cylinder. This pushing force can be transformed by a connecting rod and crank into rotational force for work. The term "steam engine" is most commonly applied to reciprocating engines as just described, although some authorities have also referred to the steam turbine and devices such as Hero's aeolipile as "steam engines". The essential feature of steam engines is that they are external combustion engines, where the working fluid is separated from the combustion products. The ideal thermodynamic cycle used to analyze this process is called the Rankine cycle. In general usage, the term steam engine can refer to either complete steam plants, such as railway steam locomotives and portable engines, or may refer to the piston or turbine machinery alone, as in the beam engine and stationary steam engine.

<span class="mw-page-title-main">Turbine</span> Device that extracts energy from a fluid flow

A turbine is a rotary mechanical device that extracts energy from a fluid flow and converts it into useful work. The work produced can be used for generating electrical power when combined with a generator. A turbine is a turbomachine with at least one moving part called a rotor assembly, which is a shaft or drum with blades attached. Moving fluid acts on the blades so that they move and impart rotational energy to the rotor.

<span class="mw-page-title-main">Boiler</span> Closed vessel in which fluid is heated

A boiler is a closed vessel in which fluid is heated. The fluid does not necessarily boil. The heated or vaporized fluid exits the boiler for use in various processes or heating applications, including water heating, central heating, boiler-based power generation, cooking, and sanitation.

<span class="mw-page-title-main">Vacuum brake</span> Train braking system

The vacuum brake is a braking system employed on trains and introduced in the mid-1860s. A variant, the automatic vacuum brake system, became almost universal in British train equipment and in countries influenced by British practice. Vacuum brakes also enjoyed a brief period of adoption in the United States, primarily on narrow-gauge railroads. Their limitations caused them to be progressively superseded by compressed air systems starting in the United Kingdom from the 1970s onward. The vacuum brake system is now obsolete; it is not in large-scale usage anywhere in the world, other than in South Africa, largely supplanted by air brakes.

<span class="mw-page-title-main">Nozzle</span> Device used to direct the flow of a fluid

A nozzle is a device designed to control the direction or characteristics of a fluid flow as it exits an enclosed chamber or pipe.

<span class="mw-page-title-main">Venturi effect</span> Reduced pressure caused by a flow restriction in a tube or pipe

The Venturi effect is the reduction in fluid pressure that results when a moving fluid speeds up as it flows through a constricted section of a pipe. The Venturi effect is named after its discoverer, the 18th-century Italian physicist Giovanni Battista Venturi.

A vacuum ejector, or simply ejector is a type of vacuum pump, which produces vacuum by means of the Venturi effect.

A propelling nozzle is a nozzle that converts the internal energy of a working gas into propulsive force; it is the nozzle, which forms a jet, that separates a gas turbine, or gas generator, from a jet engine.

<span class="mw-page-title-main">Turbomachinery</span> Machine for exchanging energy with a fluid

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<span class="mw-page-title-main">Surface condenser</span> Steam engine component

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Entrainment is the transport of fluid across an interface between two bodies of fluid by a shear-induced turbulent flux. Entrainment is important in turbulent jets, plumes, and gravity currents, and is an ongoing topic of research.

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<span class="mw-page-title-main">Rocket engine nozzle</span> Type of propelling nozzle

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<span class="mw-page-title-main">Venturi scrubber</span> Air pollution control technology

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<span class="mw-page-title-main">Spray nozzle</span> Device that facilitates dispersion of liquid into a spray

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<span class="mw-page-title-main">Boiler (power generation)</span> High pressure steam generator

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The counter-pressure brake, also named the Riggenbach counter-pressure brake after its inventor, Niklaus Riggenbach, is a dynamic railway brake on steam locomotives that brakes the locomotive using the driving cylinders. In doing so it reduces wear and tear and overheating of the driving wheel tyres and brake blocks and enables a continuously high brake force to be applied. The brake works by using the cylinders as air compressors and converting kinetic energy into heat. Steam is emitted during braking but this does not come from the boiler, it is produced by evaporation of water used to cool the cylinders.

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<span class="mw-page-title-main">Chimney (locomotive)</span>

The chimney is the part of a steam locomotive through which smoke leaves the boiler. As well, steam locomotive exhaust systems typically vent cylinder steam exhaust through the chimney, to enhance the draught through the boiler. Chimneys are designed to carry the exhaust steam and smoke clear of the driver's line of sight while remaining short enough to clear overhead structures. Some chimneys included apparatus to suppress the dispersal of sparks.

References

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  8. “THE STEAM INJECTOR.” BY MR.F.T.BARWELL, G.W.R. MECHANICS’ INSTITUTE. SWINDON ENGINEERING SOCIETY. TRANSACTIONS, 1929-30. ORDINARY MEETING. — JANUARY 21ST, 1930
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  11. Anderson, David N.; O'Day, Russell M. H. (17 July 2013). Cab-Forward Notes Southern Pacific Railroad's Signature Locomotive (Revision 1 ed.). Sacramento, California: Gerald Rood. p. 66.
  12. The Model Injector, Ted Crawford, Tee Publishing
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  14. "Steam-assisted jet pump". General Electric. Retrieved 17 March 2011. United States Patent 4847043 ... recirculation of a coolant in a nuclear reactor

Further reading