TTIY1 ® ratrljlM WAR DEPARTMENT TECHNICAL MANUAL DISTILLING APPARATUS IV A R DEPARTMENT JULY 1945 WAR DEPARTMENT TECHNICAL MANUAL T M 8-612 This manual supersedes TM S-612, 17 July 1944. DISTILLING APPARATUS WAR DEPARTMENT JULY 19 4 5 United States Government Printing Office Washington: 1945 WAR DEPARTMENT Washington 25, D. C., 13 July 1945 TM 8-612, Distilling Apparatus, is published for the informa- tion and guidance of all concerned. AG 300.7 (31 May 45) By order of the Secretary of War: Official : G. C. MARSHALL Chief of Staff EDWARD F. WITSELL Major General Acting The Adjutant General Distribution : AAF (5) ; AGF (5) ; ASF (2) ; T of Opns (10) ; Dept (10) ; Base Comds (5) ; S Div ASF (1) ; SvC (5) ; PE (2) ; ASF Dep (Med Sec) (10) ; Dep 8 (ZI) (25) except St. Louis Med Dep (100) ; GH (4) ; SH (2) ; Convalescent H (2) ; USMA (2) ; A (2) ; CHQ (2) ; AF (5) ; T/O and E-187 (2) ; 8-510 (2) ; 8-550 (4) ; 8-560 (2) ; 8-572S (2) ; 8-580 (3) ; 8-581 (3) ; 8-590 (2) ; 8-610 (1) ; 8-611 (1) ; 8-667 (2). Refer to FM 21-6 for explanation of distribution formula. CONTENTS Paragraph Page PART ONE. INTRODUCTION. Section I. General. Scope 1 1 Records 2 1 Section II. Description and tabulated data. Description 3 7 Tabulated data 4 7 Manufacturers 5 7 PART TWO. OPERATING INSTRUCTIONS. Section III. General. Scope 6 8 Section IV. Service upon receipt of equipment. Unpacking and assembling, Market Forge Models 7 8 Unpacking and assembling, Consolidated Machine Works Models 8 8 Section V. Controls and instruments. Controls .•. 9 9 Instruments 10 9 Section VI. Operation. General .r 11 10 Operation, steam-heated model 12 10 Operation, gasoline-heated model 13 10 PART THREE. MAINTENANCE INSTRUCTIONS. Section VII. General. Scope 14 20 Section VIII. Preventive maintenance services. Operator maintenance (First Echelon) 15 20 Organizational maintenance (Second Echelon) 16 20 Section IX. Trouble shooting. If the apparatus fails to produce distilled water in rated quantities 17 21 Section X. Maintenance operations. Cleaning boiler 18 21 Boiler fails to heat properly, steam model 19 21 Boiler fails to heat properly, gasoline model 20 22 Steam leak between evaporator and boiler cover 21 22 Cleaning and replacing glass gauge, 5-gallon units 22 22 APPENDIX. SHIPMENT AND STORAGE (DISASSEMBLING AND PACKING) 24 INDEX 25 This manual supersedes TM 8-612, 17 July 19Uk- PART ONE INTRODUCTION Section I. GENERAL I. Scope a. These instructions are published for the information and guidance of the personnel to whom this equipment is assigned. They contain information on the operation and maintenance of the equipment as well as descriptions of the major units and their functions in relation to the other components of the equipment. They apply to the following Medical Department items: Med. Dept. No. Nomenclature Figure 4226020 Distilling apparatus, 2-gallon, steam: 1 4226022 Distilling apparatus, 5-gallon, steam: 2 4226035 Distilling apparatus, 2-gallon, leaded gasoline: 3, 4 4226038 Distilling apparatus, 5-gallon, leaded gasoline: 5 b. These instructions are arranged in three parts: Part One, Introduction; Part Two, Operating Instructions; Part Three, Maintenance Instructions. c. All requisitions for spare parts should be submitted in ac- cordance with the latest revision of ASF Supply Catalog MED 7. 2. Records No records are required to be kept on this apparatus except as may be designated by the Medical Officer in charge. 2 1. Water level column for steam model. 2. Condenser for steam model. 3. Boiler for steam model. Figure 1. Distilling apparatus, 2-gallon, steam; manufactured by Market Forge Co. 3 Figure 2. Distilling apparatus, 5-gallon, steam; manufactured by Consolidated Machine Works, Inc. 4 1. Water level column gasoline model. 2. Condenser assembly for gasoline model. 3. Boiler for gasoline model. 4. Gasoline burner. Figure 3. Distilling apparatus, 2-gallon, leaded gasoline; manufactured by Market Forge Co. 5 1. Water level column. 2. Condenser assembly for gasoline model. 3. Boiler for gasoline model. 4. Gasoline burner. Figure 4. Distilling apparatus, 2-gallon, leaded gasoline; manufactured by Consolidated Machine Works, Inc. 6 Figure 5. Distilling apparatus, 5-gallon, leaded gasoline; manufactured by Consolidated Machine Works, Inc. Section II. DESCRIPTION AND TABULATED DATA 3. Description The distilling apparatuses are standard type water stills used for the production of distilled water. They are issued in two models: gasoline-heated and steam-heated models. This manual covers the two gallon and five gallon sizes of both models. 4. Tabulated Data See chart I. 5. Manufacturers a. Market Forge Co., (Aetna Water Still Co.) Everett, Mass. Model KL-2A, Gasoline heated, Item No. 4226035. Model SL-2, Steam heated, Item No. 4226020. h. Consolidated Machine Works, Inc. Model GLV-2, Gasoline heated, Item No. 4226035. Model GLV-5, Gasoline heated, Item No. 4226038. Model SLV-5, Steam heated, Item No. 4226022. Chart I. 2-gallon steam heated 2-gallon gasoline heated 5-gallon steam heated 5-gallon gasoline heated Production per hour 2 gallons 2 gallons 5 gallons 5 gallons Fuel consumption per hour. 18 pounds steam. 1 Vz pints gasoline. 36 pounds steam. 3 pints gasoline. Water line inside diameter. Vs inch Vs inch Vs inch Vs inch Waste line inside diameter. % inch % inch % inch % inch Steam line inside % inch Vz inch diameter. Cooling water required. 16 gallons per hour. 16 gallons per hour. 40 gallons per hour. 40 gallons per hour. PART TWO OPERATING INSTRUCTIONS Section III. GENERAL 6. Scope Part Two contains information for the guidance of the personnel responsible for the operation of this equipment. It contains infor- mation on the operation of the equipment with the description and location of the controls and instruments. Note. Failure or unsatisfactory performance of equipment will be reported on WD AGO Form 468. Section IV. SERVICE UPON RECEIPT OF EQUIPMENT 7. Unpacking and Assembling, Market Forge Models a. Open the shipping box carefully. b. Remove the paper packing and excelsior so as to uncover the still completely. c. Remove the still from the shipping box. d. The still as packed for shipment is completely assembled and ready for operation as soon as all particles of excelsior and pack- ing material have been removed and the heating and water con- nections have been made. 8. Unpacking and Assembling, Consolidated Machine Works Models a. Gasoline-heated model. (1) Open the shipping box care- fully. (2) Remove the paper packing and excelsior so as to uncover the parts of the still. (3) Remove the condenser assembly from the box and clean off all particles of excelsior or packing material and put the condenser in a place where it will not be damaged. (4) Remove the remainder of the still from the packing box and clean off all packing material from it. 9 (5) Place the condenser on the boiler and secure it by means of the four cover locks and wing screws which hold the condenser assembly in place. (6) Connect the tube to the fittings on the condenser. The pre- heated water tube drains into the water level column. b. Steam-heated model. (1) Open the shipping box carefully. (2) Remove all braces, being careful not to damage the still. (3) Remove all packing material from the still. (4) The still as received is completely assembled. (5) Connect the water and steam connections. Section V. CONTROLS AND INSTRUMENTS 9. Controls a. The controls of the gasoline-heated models are described in TM 8-615. b. A %-inch brass bibcock is provided with each unit for the purpose of draining the boiler. It is located at the base of the boiler. c. If there are no controls provided with the steam models for regulating the amount of steam entering the boiler, SR00507 (VALVE, steam, Jenkins No. ABTJA, % inch, complete:) may be used. For the steam return line SR00499, (TRAP, steam, % inch, 60 lbs., Webster No. 789-2, complete:) may be used. d. A water supply valve is supplied with each 5-gallon unit. e. A hard water petcock is provided for the purpose of draining off the surface water in the boiler of each 5-gallon unit. /. Two shut off valves are provided on the glass gauge assembly of the 5-gallon gasoline-heated model in case the glass gauge breaks. 10. Instruments a. A glass gauge is supplied with the 5-gallon unit. The glass gauge of the gasoline-heated model is equipped with shut off valves at the top and bottom of the gauge in case the glass breaks. The steam-heated model does not have manually controlled shut off valves on the glass gauge assembly. 10 Section VI. OPERATION I I. General The distilling apparatus is designed for operation with soft, clean water, such as is used for drinking purposes. Extremely hard, salt, or dirty water should not be used. In general the operation of all the units is essentially the same. Minor variations, however, are incorporated in the following paragraphs. 12. Operation, Steam-Heated Model a. Two-gallon unit. (1) Turn on the water supply and fill the boiler. When full, water will flow from the overflow outlet. (2) With the water flowing into the boiler and running from the overflow, turn on the steam supply. Caution: Make sure the steam pressure is between 40 and 60 pounds. Do not operate the apparatus at any other pressure. (3) In a short time the water will boil. Steam will be generated and will appear at the vent at the end of the condenser. Distilled water will flow through the condenser outlet tube. (See (6) fig. 6, and (8) fig. 7.) (4) Regulate the incoming water supply to allow a small amount of steam to escape from the vent at the end of the con- denser. The ratio of cooling water discharged at the bottom of the water level column to the distilled water output should be approxi- mately 8 to 1. (5) To stop the production of distilled water, first turn off the steam supply and then turn off the water supply. (6) When the steam and water supplies have been turned off, open the drain cock and drain all the water in the boiler. Then rinse the boiler by filling with clean, cold water and drain again. b. Five-gallon unit. The operation of the 5-gallon steam- heated model is essentially the same as the 2-gallon steam-heated model. However, on this unit the water level should be IV2 inches from the top of the glass gauge. The hard water petcock ((3) fig. 8) should be opened to allow a very small amount of water to drain continuously during operation. 13. Operation, Gasoline-Heated Model The following operating instructions apply to the gasoline-heated models manufactured by the Market Forge Co. (Aetna Water Still Co.) and the Consolidated Machine Works. a. Two-gallon unit. (1) Turn on the water supply and fill the boiler. When full, water will flow from the overflow outlet. 1. Boiler drain bibcock. 2. Overflow stem, 3. Water level column. 4. Preheated water outlet tube. 5. Water inlet tube. 6. Condenser outlet tube. 7. Cooling coil. 8. 4R03426 GASKET, evaporator top, asbestos, steam model: 9. Wing nut. 10. Riser elbow, I I. Riser tube, 12. Evaporator cover. 13. Baffle plate. 14. Complete evaporator for steam model. 15. Outside jacket for steam model. 16. Pipe connector. 17. Steam coil. 18. Evaporator bottom section. 19. Water inlet elbow. Figure 6. Details of 2-gallon steam-heated distilling apparatus; manufactured by Market Forge Co. 1. Bibcock for draining boiler. 2. Cover lock. 3. Wing nut. 4. Preheated wafer outlet tube. 5. Brass adapter. 6. Inlet water tube. 7. Asbestos gasket. 8. Condenser outlet tube. 9. Evaporator. Figure 7. Details of 2-gallon steam-heated distilling apparatus; manufactured by Consolidated Machine Works, Inc. 14 1. Boiler drain bibcock. 2. Glass gauge. 3. Hard water bibcock. 4. Glass gauge holder. 5. Preheated water outlet tube. 6. Brass adapter. 7. Water supply valve. 8. Condenser outlet tube. 9. Wing nut. 10. Cover lock. I I. Asbestos gasket for evaporator top. 12. Evaporator. 13. Steam supply valve. 14. Coupling nuts. 15. Boiler complete. Figure 8. Details of 5-gallon steam-heated distilling apparatus; manufactured by Consolidated Machine Works, Inc. 1. Boiler draincock. 2. Water level column, gasoline model. 3. 4R03436 TUBE, preheated water outlet: 4. Water inlet tube. 5. 4R03434 TUBE, condenser outlet: 6. Cooling coil. 7. 4R03424 GASKET, evaporator top, asbestos, gasoline model: 8. SR00050 NUT, 10 x 24, wing, brass, 100 to pkg.: 9. Riser elbow. 10. Riser tube. I I. Evaporator cover. 12. Baffle plate. 13. 4R03420 EVAPORATOR, gasoline model, complete: 14. Outside jacket tor gasoline model. 15. Boiler bottom section. 16. Iron support. Figure 9. Details of 2-gallon gasoline-heated distilling apparatus; manufactured by Market Forge Co. 17 (2) With the water flowing into the boiler and running from the overflow, ignite the gasoline burners. See operating instruc- tions in TM 8-615. (3) In a short time the water will boil. Steam will be generated and will appear at the vent at the end of the condenser. Distilled water will flow from the condenser outlet tube. (See (5) flg. 9.) (4) Regulate the incoming water supply to allow a small amount of steam to escape from the vent at the end of the con- denser. The ratio of cooling water discharged at the bottom of the water level column to the distilled water output should be approxi- mately 8 to 1. (5) To stop the production of distilled water, first turn off the gasoline burners and then turn off the water supply. (6) When the gasoline burners and the water supply have been turned off, open the drain cock and drain all water in the boiler. Then rinse boiler by filling with clean, cold water and drain again. b. Five-gallon unit. The operation of the 5-gallon gasoline- heated model is essentially the same as for the 2-gallon gasoline- heated model. However, on this unit the glass gauge shut off valves ((13), fig. 10) must be opened before filling the boiler with water. The water level should be 3 inches from the top of the glass gauge. (See (15) fig. 10.) The hard water petcock should be opened to allow a very small amount of water to drain continuously during operation. In the event the glass gauge breaks during operation the shut off valves on the glass gauge must be closed. 18 1. Boiler drain bibcock. 2. Hard water bibcock. 3. Evaporator. 4. Water level column. 5. Cover lock. 6. Wing nut. 7. Preheated water outlet ,tube. 8. Condenser. 9. Water supply valve. 10. Condenser outlet tube. I I. Asbestos gasket for evaporator top. 12. Boiler complete. 13. Valve stem assembly for glass gauge holder. 14. Glass gauge rods. • 15. Glass gauge. 16. Coupling nuts for glass gauge. 17. Gasoline burner. Figure 10. Details of 5-gallon gasoline-heated distilling apparatus; manufactured by Consolidated Machine Works, Inc. PART THREE MAINTENANCE INSTRUCTIONS Section VII. GENERAL 14. Scope Part Three contains information for first and second echelon maintenance. It contains information needed for service, as well as description of major units and their function in relation to other components of the equipment. Section VIII. PREVENTIVE MAINTENANCE SERVICES 15. Operator Maintenance (First Echelon) a. Before operation. The unit should be cleaned of any dirt that has collected. b. During operation. The hard water petcock should be opened to allow a small amount of water to drain off the top of the boiler on each 5-gallon unit. c. After operation. The boiler should be rinsed and drained. 16. Organizational Maintenance (Second Echelon) a. Monthly. (1) Check for proper operation of the apparatus. (2) Check for excessive lime deposits. (See pars. 19a and 20a.) (3) Check to see if a spare gasket ((7), fig. 9) for each gaso- line-heated model is with the unit. See ASF Supply Catalog MED 7 fo rreplacement. (4) Flush or clean the glass gauges on the 5-gallon units. (See par. 22.) 21 Section IX. TROUBLE SHOOTING 17. If the Apparatus Fails to Produce Distilled Water in Rated Quantities Possible causes Possible remedies a. Lime deposits in boiler. a. Clean boiler. (See par. 18.) b. Boiler fails to heat b. For gasoline models. (See properly. par. 20.) For steam models. (See par. 19.) c. Steam leak between evapo- c. Replace gasket. (See rator and boiler cover. par. 21.) Section X. MAINTENANCE OPERATIONS 18. Cleaning Boiler a. The interior of the boiler should be cleaned of lime deposits at intervals depending on the hardness of the water used. In some cases it requires cleaning every 24 hours. In all cases the boiler should be drained, rinsed with clean, cold water and drained again after each period of operation. b. To clean the boiler proceed as follows: (1) Loosen wing nuts and cover locks from the cover plate. (2) Remove the condenser assembly as a unit. (3) If the interior of the boiler is badly coated or stained, clean with PUMICE STONE, commercial, powdered, Grade No. F, one pound carton, Federal Stock No. 51-P-2700 Ord. Specification No. FXS-241, and scrub with a stiff brush. Do not use acids. (4) After cleaning, rinse thoroughly with clean, cold water and dry with a clean cloth. (5) Replace condenser assembly, making sure that the asbestos gasket is set properly between the boiler cover and the top of the boiler. A spare gasket ((7), fig, 9) should be kept with the gaso- line-heated models at all times. (6) Tighten cover locks and wing nuts. 19. Boiler Fails to Heat Properly, Steam Model a. If the boiler of the steam model is slow to heat, it may be due to an excessive lime deposit on the steam coil. Clean the outside of the coils with PUMICE STONE, commercial, powdered, Grade No. F, one pound carton, Federal Stock No. 51-P-2700 Ord. Speci- 22 fication No. FXS-241, and scrub with a stiff brush. Do not use acids. After cleaning, rinse thoroughly with clean, cold water and dry with a clean cloth. b. Slow heating of the boiler also may be due to low steam pres- sure in the steam supply line. The steam pressure should not be below 40 pounds nor above 60 pounds. c. The distilling apparatus is a factory assembled unit and should not be dismantled in the field. There are no mechanical parts to fail. If the apparatus does not operate and a thorough cleansing will not restore its efficiency, it should be sent to a higher echelon for repair. 20. Boiler Fails to Heat Properly, Gasoline Model a. If the boiler of the gasoline model is slow to heat, it may be due to an excessive lime deposit on the bottom of the boiler. Clean the boiler as described in paragraph 18. b. Slow heating also may be due to improper operation of the gasoline burners. See TM 8-615 for operation and maintenance. c. The distilling apparatus is a factory assembled unit and should not be dismantled in the field. There are no mechanical parts to fail other than those in the burners. If the apparatus does not operate and a thorough cleansing will not restore its efficiency, it should be sent to a higher echelon for repair. 21. Steam Leak Between Evaporator and Boiler Cover If steam escapes between the evaporator and boiler cover, it may be necessary to replace the asbestos gasket found there. A spare asbestos gasket ((7), fig. 9, or (11), fig. 10) should be kept with each gasoline model at all times. Replace as follows: a. Loosen wing nuts and cover locks holding cover in place. b. Remove condenser assembly. c. Remove gasket. d. Replace with new gasket and reassemble. Note. Certain spare parts for the Market Forge apparatus were pm-chased from Consolidated Machine Works to specifications for the Market Forge models and will fit this unit. If spare parts are received for use on the Market Forge (Aetna Water Still Co.) models and they do not have the appearance of the part being replaced, be certain to check to see that they do not fit be- fore returning. 22. Cleaning and Replacing Glass Gauge, 5-Gallon Units The glass gauge on the 5-gallon distilling apparatus should be flushed at least once a month to remove any accumulation of lime deposits within the glass gauge. If this does not remove the de- posits, the glass gauge may be removed and cleaned as follows; 23 a. Gasoline model. (1) Remove the glass gauge rods. (See (14), fig. 10.) (2) Remove the upper valve stem assembly ((13), fig. 10) from the holder. (3) Loosen the glass gauge coupling nuts ((16), fig. 10) until free from the holders. (4) Remove the glass gauge ((15), fig. 10) by pushing the glass up into the upper glass gauge holder until the bottom of the gauge is free from the lower holder and then pull the gauge downward and out of the holder. Caution: Do not lose the gaskets and washers on the glass gauge. (5) Clean the gauge by drawing a moist cloth through the glass gauge. (6) Reassemble the gauge by reversing the above procedure. If the glass has been broken, be certain to remove all particles of glass before replacing and reassembling. b. Steam model. (1) Loosen the glass gauge coupling nuts ((14), fig. 8) until free of the holders. (2) Remove the glass gauge ((2), fig. 8) by pushing the glass up into the upper glass gauge holder until the bottom of the gauge is free from the lower holder and then pull the gauge downward and out of the holder. (3) Clean the gauge by drawing a moist cloth through the glass gauge. (4) Reassemble the gauge by reversing the above procedure. If the glass has been broken, be certain to remove all particles of glass before replacing and reassembling. APPENDIX SHIPMENT AND STORAGE (DISASSEMBLING AND PACKING) 1. Be certain the steam supply is shut off or in the case of the gaso- line-heated models, that the gasoline burner is extinguished. 2. Disconnect the water connections. 3. Disconnect the steam lines of the steam-heated model. 4. Clean and dry the still thoroughly. 5. Pack the unit completely assembled in a stout box or crate using paper, rags or similar materials to keep the still from moving in its container during transit. Caution: If the gasoline-heated model is to be stored or shipped, the gasoline must be drained from the burner tank, (See TM 8-615.) INDEX Paragraph Page Assembling, Consolidated Machine Works models 8 8 Assembling, Market Forge models 7 8 Boiler, cleaning ; 18 21 Boiler fails to heat properly, steam model 19 21 Boiler fails to heat properly, gasoline model 20 22 Cleaning: Boiler 18 21 Glass gauge 22 22 Controls 9 8 Data 4 7 Description 3 7 Disassembling App. 24 Gasoline burner, controls 9a 9 Gasoline-heated model, operation 13 10 Glass gauge, cleaning 22 22 Instruments 10 9 Maintenance operations 18—22 21 Manufacturers 5 7 Operation, gasoline-heated models 13 10 Operation, steam-heated models 12 10 Operator maintenance (First Echelon) 15 20 Operator maintenance (Second Echelon) 16 20 Packing App. 24 Preventive maintenance services 15—16 20 Records 2 1 Steam-heated model, operation 12 10 Steam leak 21 22 Trouble shooting 17 20 Unpacking and assembling: Consolidated Machine Works model 8 8 Market Forge models 7 8 * U. s. GOVERNMENT PRINTING OFFICE: 1945—TM-226