I also looked up the cloth merchant that I’d contracted with last summer. We made arrangements for delivering the two thousand yards of cloth agreed upon. He wasn't happy about the deal, because the price of cloth had dropped since we had agreed on the price, and he would loose money by honoring the agreement. I wouldn't let him off, though. I never told him to be a capitalist!
Then back to Three Walls where people still weren’t too clear about what had happened. It took a full day with my foremen to settle out who would be going where to do what.
And besides all of the above, work was going on at Three Walls, and we had to agree on a schedule to keep things going even though we were losing two-thirds of our best men and having to hire a bunch of rookies. Most of those going to Eagle Nest would be coming back, but the transfers to Copper City would be permanent.
I was having a wonderful time!
I had the new buildings drawn up in four days, largely because of Sir Vladimir’s help. He was becoming a good draftsman, and I'd make an engineer out of him yet.
But looking at the amount of wood that had to be sawn in a few months, it would take three of our walking-beam sawmills to do the job at each of the new installations.
The quality of the work turned out by the brass works had been steadily increasing. It was time to try our hands at a steam-powered sawmill.
We were casting pipes. A tubular boiler wouldn’t be difficult. We were machining bearings and bushings. Cylinders, pistons, and rods wouldn't be that much harder. We were making high-pressure water valves. Steam valves should be possible.
The only hang-up was how to fasten the end-caps to the cylinders. I didn’t see any way to do that except with steel machine screws. The few screws we had made so far had been filed by hand, which was expensive and not nearly accurate enough.
I needed an engine lathe to accurately cut screws and to make good taps and dies. And an engine lathe needs accurate screws to feed the tool along the stock. I had to have a screw to make a screw!
I laid the problem aside, hoping my subconscious would come up with something, and worked on the rest of the engine. We had to cut huge logs, two and three yards thick, so a circular saw would have had to be six yards across. This was beyond our capabilities. We could probably make a big bandsaw blade, but such a blade has to be very flexible, and I doubted the quality of our steel. I sketched up a big enough bandsaw and it was huge, difficult to move, hard to make, and expensive. KISS.
Then I took one of our four-yard ripsaws and sketched a three-yard-long cylinder at each end of it. By alternately pressurizing the rod ends of the cylinders, they would pull the saw blade back and forth. I set the cylinders horizontally, so the machine wouldn’t have to be built in a pit. A manually operated screw pulled the log into the blade, and a mechanism for holding the log at the proper angle was straightforward.
A tubular boiler, a pressure gauge, and a safety relief valve came off my board within a day, and finally I put the whole thing on wheels. It might take a dozen mules to move it, but at least we wouldn’t have to disassemble it to move it. In five days flat I had a complete set of drawings.
The world’s first steam engine!
But I still hadn’t figured out how to make a good screw. Finally, I just drew up a simple engine lathe, even though I didn't see how we could possibly build one. By this time, we had pretty much duplicated the machinery from the brass works at Three Walls, complete with pigs in huge hamster cages turning the lathes, so I gave the drawings to Ilya and told him to make me one.
Ilya was a good man at a forge, but he didn’t have the machining experience of the Krakowski brothers. I gave this difficult project to him because the Krakowski brothers were reasonable enough to ask questions until they understood something, and I didn't have the answers to match their questions.
Ilya, on the other hand, was never reasonable. His ego was such that he would never admit that there was anything that he didn’t quite grasp. He was belligerent, intolerant, and bullheaded, but he wasn't stupid.
The engine lathe would be the most complicated piece of equipment we owned, but I gave the project to him as casually as if I was asking for an axe head. I simply explained what it did and why, and asked to have it done as soon as possible. He stared at the drawings for a few moments and then said that if I wanted the silly thing, he’d build it.
For the next five weeks, it was hard to get anything else out of the blacksmiths, and repair work was done only grudgingly. I finally had to step in and split the section into a forging group and a machining group, just to keep the carpenters and masons in tools.
At one point I was walking through the plant and saw Ilya carefully wrapping a woman’s bright red ribbon around a smooth brass rod, and carefully scribing on the brass where the top of the ribbon came to as he went along. I didn't say a word.
Another time I saw him deliberately pouring fine sand on a set of running gears, while on another machine one of his assistants was running an iron nut back and forth on a long brass screw. The nut was in two halves and clamped back together, and it too was dusted with fine sand. The assistant said that he had been doing this boring work for two weeks, but I didn’t want to get involved. If Ilya somehow did the job, great. If he fell on his ass, the humiliating experience might make him easier to live with.
But Ilya. did it. The engine lathe worked better than I had expected, and Ilya’s ego was so monstrous that he wouldn't even accept praise for it. He pretended that he could do that sort of thing every day. So I put him in charge of making the steam-powered sawmills, and told him not to take so long this time.
Most modem factories are built on flat, level land. My material handling equipment was limited to men with wheelbarrows, and the coal came out of the mountain several hundred yards above the valley floor. I used the slope of the valley walls to help out.
From the tunnel mouth, loads of coal were dumped in a pile almost at the door. Below that was a cleaning and sorting area and the tops of the coke ovens were lower still. I built the top of the blast furnace lower than the bottom of the coke oven, about level with the entrance to the boys’ cave, where the iron ore came out.
It was still wheelbarrow work, but at least we didn’t have to push stuff uphill.
Ilya was vastly skeptical about using anything but charcoal to make iron, but I bullied him into it and with our coke and our iron ore, he eventually turned out decent wrought iron. He insisted that charcoal was better than coke, especially for the cementation process of making steel, but that last took very little charcoal.
As soon as the weather broke, the masons were busy assembling the blast furnace. They had been cutting sandstone blocks for it all winter long, and we had good supplies of coke and iron ore.
After five days of steady burning, we made our first pour, knocking in the clay plug with a long iron rod, and getting out of the way as a long stream of molten iron sprayed out. After that we tapped it four times a day.
Chemical engineers often refer to themselves as “bucket chemists,” as opposed to the “test tube chemists” who work in laboratories, because they often do their experiments with large quantities of chemicals. Reaction rates and sometimes even the end products can vary depending on the quantities used, so these people mix things by the bucketful.
I was a bucket chemist of vast proportions. I got the blast furnace going by building a full-size blast furnace and experimenting for months with the quantities of coke, ore, and limestone required. What little iron we turned out in those first months was simply tossed into a pile for later refining, because it wasn’t worth much in its present state.
It was simply that there was no way of doing things on a smaller scale, not without some way of measuring temperatures. Brute force had to substitute for finesse.
Did we need more air in the furnace? We didn’t know. Build more bellows, put more people to pumping them and see what happens!
At first, all we could do with the pig iron was to cast it in long trough
s formed in the sand, but we could always melt it down later by throwing it back into the furnace. I had Mikhail Krakowski come down and set up our casting operation for us. He used the system he knew, pouring into hot clay molds rather than the sandcasting used in modem foundries. But it worked, and I saw no need to change things. If anything, he got a much better surface finish using clay than I had ever seen using sand.
So the stench and dirt of a blast furnace was added to the stink of the coke ovens.
The bloomery we built next to the blast furnace was less experimental. It produced wrought iron the same way Ilya had back at Okoitz, only on a far larger scale. One of the first steam-powered machines built after the steam saws was a steam hammer to beat the wrought iron blooms, taken from the furnace, into iron rods. It worked on waste heat from the furnace itself, a tubular boiler having been built in the chimney.
Ilya was proud of that bloomery, and worked it at a fine peak of efficiency. But he hated the blast furnace. He could see little use for cast iron, which was made at much higher temperatures, had vastly more impurities and was so brittle that it had to be cast into its final shape, because you couldn’t bend it without breaking it. What use was a piece of iron if you couldn't beat on it?
I finally had to put another man in charge of the blast furnace, since Ilya considered it a waste of good ore and coke.
But cast iron is a useful material. Before too long, we were producing a line of consumer goods from it, potbellied stoves, pots and pans, and large kitchen ranges that my great grandmother would have been proud of. And cast iron is the best material for making large machine bases. It is rigid, dimensionally stable, and the fibrous crystalline structure absorbs vibrations. If you look at cast iron under a microscope, it looks like a pile of needles-not that we had a microscope.
Furthermore, cast iron is the starting material for making large quantities of steel, and it was going to take large quantities to beat the Mongols.
But try convincing Ilya of that!
Chapter Seven
In the twentieth century, there are many racial stereotypes, and most of them are derogatory. You know the sort I mean. Englishmen are all stiff, formal, and supercilious. Frenchmen are all drunkards and hung up on illicit sex. Germans are all warmongers who spend their off time making ridiculously complicated toys. Blacks are all lazy criminals. Americans are all loud, boorish, and rich. Jews are all sneaky shysters. Poles always do everything backward.
Everybody knows that these statements are mostly nonsense. The people of any group are diversified. Some of them are good and wise, some are bad and stupid, and most are indifferent.
Yet there is a grain of truth in many of the stereotypes. The British are more formal than most people. The French per capita consumption of wine is frightening, enough so that any person from another country who drank what they average would be considered an alcoholic. And historically, the Germans have started an awful lot of wars, losing most of them.
While I am not going to admit that Poles do everything backward, I will admit that we are very good at looking at things from a different angle than most other peoples. The typical Pole has no difficulty dealing with a concept like the square root of a negative one, for example, a thing that can make a tightly logical Englishman catatonic.
That particular concept is regularly used in electrical design, and in America, where there has been a tendency for different nationalities to gravitate into specific trades, perhaps half the electrical engineers claim Polish descent. In the same manner, many of the architects and construction workers are Italian, and the Arabs have started to dominate the mercantile trades.
It’s not that any of these nationalities forces the others out of their bailiwick. It's that an individual tends to work at what he can do best. What I am trying to lead up to is why I built a milehigh smokestack, sideways.
I suppose that I could claim that structural limitations in the materials available and the absence of certain types of machinery necessitated building the stack against the side of the mountain, but that’s not the way it happened.
Besides setting up to produce cast iron, wrought iron, and lime for mortar, I wanted to produce bricks, tiles, and clay pipes. I’d once read about an ancient Chinese invention called a dragon furnace, a long kiln built up the side of a mountain. You filled the kiln with unfired products and started a fire at the bottom. The rest of the kiln functioned as a chimney, and the bricks farther up were at least warmed up and dried out as those on the bottom were being fired.
Then you started another fire farther up in the furnace. Air coming up the furnace was heated by the hot bricks near the bottom, so it took less fuel to bake the bricks farther up. As time went on, you kept starting new fires farther and farther up, letting the old ones die out. It took a week to fire all the bricks in the furnace, at which time you took out all the baked bricks and put in green ones. The system had a lot in common with the modem reverse-flow system.
We soon added a second furnace along side the first so that we could keep working continuously.
One of the coke oven workers was being ragged by his wife because of the stench he spent all day generating. He came to me with a proposal for a set of flues to take the coke oven fumes to the dragon furnaces and so get them out or,“ the valley. He even had a well thought out set of drawings showing how this could be done. With only minor changes, we tried it and it worked. The stench was reduced and the valley became a good deal more livable.”
Furthermore, the fumes contained a fair amount of unburnt gases which were ignited in the hot dragon furnace, and fuel consumption in the dragon furnaces went down. As time went on, we made the dragon furnaces longer and longer until they reached the top of the highest mountain there. Then we built a smokestack at the top, and everything noxious went up it.
I made the man the guest of honor at the next Saturday night dance, publicly gave him three hundred pence as a bonus, and promoted him as soon as possible after that.
This got me the damndest collection of weird suggestions you could ever imagine. I’d wanted to encourage thinking on the part of the workers, but I hadn't expected to be inundated by dumb ideas. I finally had to set up a review system, where suggestions had to filter up through channels, and pay additional bonuses to workers' bosses so that they wouldn't squash everything.
But the system worked. Not only did it result in a lot of useful devices, but it singled out workers who could benefit from further engineering training. As the years went on, I had to do less and less of the design work myself. This was good, because management work was taking up more and more of my time.
Eventually we got notice that the duke would be arriving the next morning, so ’ I had the band ready. They had collected or had made seven brass instruments, mostly trumpets, and I had taught them a few fanfares. That is to say, I whistled the tunes and they figured out how to make them come out of a horn. Their wives had improvised some gaudy band uniforms, and they made a fairly impressive display, along with their drummers, playing the Star Wars theme from the balcony as the duke rode in.
Duke Henryk arrived with his son, his armorer, and twenty men. Since I’d promised them two complete suits of plate armor, I put the girls to making each of them a suit of parchment armor, as they had done for me.
A few months before, at my Trial by Combat, my helmet had been bashed around and jammed at a right angle from where it should have been, so I could only look over my right shoulder. It darned nearly was the death of me. Naturally, I had redesigned the helmet. Instead of a clamshell affair that split down the middle and required a helper to put on, the new version looked sort of like a “Darth Vader” helmet with the bottom edge fitting into the ring around my collar. A separate piece, called a beaver, fit into the front half of the ring and covered the bottom of my face. Two easily removed pins fastened the beaver to the rest of the helmet, and a visor could be flipped down to protect the eyes at the price of decent visibility. The big advantage was that you could put
it on and take it off by yourself, even if it was bent.
Naturally, his grace and the prince got the new model helmets.
I’d also had the smiths do a lot of preparatory work, making up each of the pieces in advance, but oversized, so that they need only be trimmed down, finished, and assembled. Even this took the whole crew ten days to do, and I didn't let them off for Sunday, for fear of boring our highborn guests.
As it turned out, I needn’t have worried, for the duke stayed two days longer than he had to. He was vastly impressed with the plumbing in our bathrooms. He demanded that I duplicate the system at both Piast Castle in Wroclaw and Wawel Castle in Cracow. I told him that it would be expensive, but he didn't seem to care. He wanted it, so he got it. He even paid the bill without complaining.
I showed him my plans for what I’d started calling Copper City, and he seemed pleased. “Just so it works, boy!”
We were lucky in that Ilya had just completed the first steam sawmill, or I don’t think I could have gotten him to work on armor, duke and prince or no duke and prince. The walkingbeam sawmill was still in use, how ever, so I showed that to my guests first. They watched sixty women walking back and forth and the huge logs being cut into boards for half an hour. They were suitably impressed. Then we demonstrated the new steam mill, which cut more than twice as fast as the walking-beam mill, and required only a single operator. They were astounded.
“Damn, boy! That thing has the power of two hundred women!” The name of the unit stuck. At one time I had been worried that we would use “pig power” the way the Americans use “horse power,” much of our early machinery being powered by pigs in huge hamster cages. But after the duke’s statement, all our steam engines got rated in woman power, and operators talked about how many women they tended. I tried to stop it, but I couldn't. The best I could do was to redefine it so that it would fit into our system of weights and measures.
The Radiant Warrior Page 8
