NEW SOUTH WALES GOVERNMENT RAILWAYS BOILER MAINTENANCE REGULATIONS

MAY, 1938 Department of Railways, New South Wales Boiler Maintenance Regulations Page ii

This book is the property of the Commissioner for Railways, and is issued for the guidance of those concerned in the inspection, repair, construction and maintenance of locomotive, stationary and portable boilers, and unfired pressure vessels, in the service of the Department, with the exception of those controlled by the Chief Electrical Engineer. The Officer to whom this book is issued shall make himself acquainted with the regulations contained herein, and shall be held responsible for keeping the book clean and in good condition. He shall insert new, and return amended pages as may be directed from time to time by the Boiler Engineer. The book shall be located at the depot where the Officer is stationed, and shall remain there, unless recalled, irrespective of any staff changes. The regulations contained herein, and appended hereto, shall be complied with in all respects. All previous circulars dealing with subjects covered by these regulations are hereby cancelled insofar as those subjects are concerned.

F. HODGSON H. YOUNG Boiler Engineer. Chief Mechanical Engineer. May, 1938. Department of Railways, New South Wales Boiler Maintenance Regulations Page iii

CONTENTS

SECTION 1 GENERAL REGULATIONS COVERING THE INSPECTION AND TESTING OF LOCOMOTIVE BOILERS

Clause: Page

1.01 Internal examinations by Boiler Inspectors and preparation of boiler 1 1.02 Submission of boiler inspection reports 1a 1.03 Submission of estimates for repairs with inspection reports 1a 1.04 Filing of inspection reports 2 1.05 Boiler history record 2 1.06 Repairs to boilers on locomotives in workshops 2 1.07 Submission of reports for repairs to boilers on locomotives in workshops 2 1.08 Testing of new boiler plates 3 1.09 Marking of plate diagrams for new or re-built boilers 3 1.10 Inspection of work during construction of new boilers 3 1.11 Numbering of new boilers 3 1.12 Tests on completion of new boilers 4 1.13 Submission of report upon first inspection of new boilers 4 1.14 Service certificate 4 1.15 Co-operation to obtain efficient work 4

SECTION 2 INSPECTION, REPAIR AND TESTING OF LOCOMOTIVE BOILERS AT DEPOTS 2.01 Boilers due for examination or test 5 2.02 Examination and repairs 5 2.03 Filing of reports 5 2.04 Suspension of certificate during repairs 5 2.05 Stopping locomotives for boiler repairs 6 2.06 Submission of reports on boilers repaired at depots and not supervised by a Boiler Inspector 6 2.07 Boiler repair book 6

SECTION 3 HYDROSTATIC AND STEAM TESTS FOR LOCOMOTIVE BOILERS WITH COPPER FIREBOXES Clause: Page

3.01 Grouping for test purposes 7 3.02 Hydrostatic test 7 3.03 Hydrostatic test pressures 8 3.04 Hydrostatic test with mountings 8 3.05 Variations in pressure during Hydrostatic test 9 3.06 Steam test 9 3.07 Steam test pressures 9 3.08 Variations in pressure during steam test 10 3.09 Setting safety valves 10 Department of Railways, New South Wales Boiler Maintenance Regulations Page iv

SECTION 4 INSTRUCTIONS FOR EXAMINATION, REPAIR, AND MAINTENANCE OF LOCOMOTIVE BOILERS AT DEPOTS Clause: Page

4.01 Monthly examination of boiler 11 4.02 Supervision of work by Sub-foreman or Leading Boilermaker 11a 4.03 Daily supervision by Officer-in-Charge 11a 4.04 Repairs at monthly examinations 12 4.05 Repairs for broken rivets in copper fireboxes 12 4.06 Attention to leakages 12 4.07 Foreign matter in boilers 12 4.08 Monthly examination of firebox and firebox shell plates 13 4.09 Special examination of vital positions 13 4.10 Lubrication of expansion brackets 13 4.11 Progress of pitting and corrosion 13 4.12 Boiler Inspector’s report of condition of boilers at depots 14 4.13 Lax supervision and faulty or neglected repairs 14 4.14 Co-operation to obtain efficient work 14 4.15 Daily examination of fireboxes 14 4.16 Daily examination of smokeboxes 14a 4.17 Special examination of fire prevention appliances 14a 4.17a Examination of boilers on locomotives away from home depot 14a 4.17b Prevention of cold air entering fireboxes 15

SECTION 4a EXAMINATION AND MAINTENANCE OF WATER GAUGE COLUMNS Clause: Page

4.18 Responsibility of Steam Shed Inspectors 15a 4.19 Water gauge column steam pipes 15a 4.20 Cleaning steam and water-way passages of water gauge columns 15b 4.21 Maintenance of water gauge column cocks 15b

SECTION 5 INTERNAL EXAMINATION PERIODS AND SERVICE LIMITS FOR LOCOMOTIVE BOILERS Clause: Page

5.01 Internal examination periods for locomotive boilers 16 5.02 Examination and test periods of first term boilers having copper fireboxes and tubes 17 5.03 Examination and test periods of second and subsequent term boilers having copper firebox and tubes 17 5.04 Examination and test periods of first term boilers having all steel fireboxes and tubes 17 5.05 Examination and test periods of second and subsequent term boilers having all steel fireboxes and tubes 18 5.06 Examination and test periods of first term boilers having composite fireboxes, i.e., steel tubes and tubeplates 18 Department of Railways, New South Wales Boiler Maintenance Regulations Page v

5.07 Examination and test periods of second and subsequent term boilers having composite fireboxes, i.e., steel tubes and tubeplates 18 5.08 Preparation of old boilers for internal examination 18a 5.09 Reclamation of usable material for condemned boilers 18a

SECTION 6 CROWN STAY EXAMINATIONS FOR LOCOMOTIVE BOILERS Clause: Page

6.01 Crown stay examinations by the Boiler Inspector 19 6.02 Issue of monthly list of boilers due for crown stay examination 19 6.03 Crown stay diagrams 19 6.04 Method of indicating withdrawn crown stays 20 6.05 Number of crown stays to be removed for examination 20 6.06 Reporting crown stay withdrawals and attention 20 6.07 Correct fitting of crown stays 21 6.08 Cutting off points of crown stays in Belpaire Boilers 21 6.09 Evidence of defective crown stays 21 6.10 Cleaning of crown stays 21 6.11 Condemning diameter of crown stays 21 6.12 xxxx x 6.13 Examination of rigid type crown stays in boilers with round top fireboxes 22 6.14 Plugging tell-tale holes in crown stays 22 6.15 Broken crown stays 22

SECTION 7 WALL STAY EXAMINATIONS FOR LOCOMOTIVE BOILERS Clause: Page

7.01 Examination of wall stays in fireboxes 23 7.02 Removal of clothing sheets to facilitate examination for broken stays 23 7.03 Importance of wall stay inspections 23 7.04 Broken wall stays 23 7.05 Cleaning of tell-tale holes in throat stays when brick arch is removed 23 7.06 Removal of side tanks and clothing sheets for wall stay examinations 24 7.07 Submission of wall stay diagrams 24 7.08 Plugging or hammering over tell-tale holes in wall stays 24

SECTION 8 COPPER TUBEPLATE EXAMINATIONS FOR LOCOMOTIVE BOILERS Clause: Page

8.01 Examination of copper tubeplates 25 8.02 Removal of tubes for purpose of inspection 25 8.03 Remove of additional tubes for purpose of inspection 25 8.04 Report on tubeplate thickness and condition 26 8.05 Inspection of interior of boiler whenever tubes are removed 26 Department of Railways, New South Wales Boiler Maintenance Regulations Page vi

SECTION 9 TUBES FOR LOCOMOTIVE BOILERS; EXAMINATION, APPLICATION AND MAINTENANCE Clause: Page

9.01 Record of changed tubes 27 9.02 Examination of tubes 27 9.03 Maintenance of flues and tubes 27 9.04 Application of tube ferrules 29 9.05 Use of oxy-acetylene torches inside fireboxes 29 9.06 Driving up tubes 29 9.07 Testing after tube attention 29 9.08 Projection of boiler tubes in smokeboxes 30 9.09 Sag in tubes 30 9.10 Condition of expanded ends of sagged tubes 30 9.11 Cleaning of superheater and small tubes 30a

SECTION 10 STUDS IN LOCOMOTIVE BOILERS Clause: Page

10.01 Breaking off studs 31 10.02 Restriction on removal of studs 31

SECTION 11 BRICK ARCH STUDS IN LOCOMOTIVE BOILERS Clause: Page

11.01 Reconditioning brick arch stud holes 32 11.02 Oversize brick arch studs 32 11.03 Brick arch studs out of alignment, plugged holes, and plate thickness and condition 32 11.04 Combined brick arch stud and wall stay 32a

SECTION 12 FUSIBLE PLUGS FOR LOCOMOTIVE BOILERS Clause: Page

12.01 Types of plugs and fusible fillings 33 12.02 Examination and renewal 33 12.03 Return of used plugs and ordering of new stock 33 12.04 Reporting examination and renewal of fusible plugs 33 12.05 Renewal of plugs in locomotives leaving workshops 34 12.06 Graphite lubricant on threads of plugs 34 12.07 Oil or grease on tops of plugs 34 12.08 Examination of plugs for defects 34 Department of Railways, New South Wales Boiler Maintenance Regulations Page vii

SECTION 13 DAMAGE TO LOCOMOTIVE BOILERS THROUGH SHORTAGE OF WATER OR OTHER CAUSES Clause: Page

13.01 Inspection of fireboxes on arrival of locomotive at depots 35 13.02 Sealing fireboxes when damage is suspected 35 13.03 Sealing firehole doors 35 13.04 Display of ‘Boiler Empty’ boards 36 13.05 Examination of boilers involved in accidents 36

SECTION 14 PAINTING INSIDE LOCOMOTIVE BOILERS WITH BITUMINOUS PAINT Clause: Page

14.01 Repaired boilers 37 14.02 New boilers 37 14.03 Application of paint 37 14.04 Inflammable vapour 38 14.05 Working in enclosed spaces 38 14.06 Supplies of paint 38

SECTION 15 INSTRUCTIONS FOR THE CARE AND MAINTENANCE OF ARCH TUBES IN LOCOMOTIVE BOILERS Clause: Page

15.01 Responsibility of Steamshed Inspector 39 15.02 Alteration to cleaning period due to bad water conditions 39 15.03 Officer to carry out examination 40 15.04 Periodical examinations 40 15.05 Exterior examination of arch tubes 40 15.06 Internal examination of arch tubes 40 15.07 Adherence of clinker to tubes 40 15.08 Projection of flared ends of arch tubes not fitted with sleeves 41 15.09 Compressed air supply for arch tube cleaners 41 15.10 Storage of cleaners when not in use 41 15.11 Lubricating cleaners 41 15.12 Examination of cutters, etc., in cleaners 41 15.13 Cleaners requiring repairs 41 15.14 Operation of cleaners 41 15.15 Maintenance of arch tubes 42 15.16 Examination for brick wear 42 15.17 Prohibition of welding 42 15.18 Application of arch tubes 42 15.19 Cutting to length 43 15.20 Cutting and squaring ends of arch tubes 43 15.21 Annealing arch tubes 43 15.22 Prohibition of cooling in water 43 15.23 Setting arch tubes 43 15.24 Reporting renewals 44 15.25 Oversize holes for arch tubes without sleeves 44 Department of Railways, New South Wales Boiler Maintenance Regulations Page viii

15.26 Replacing arch tube plugs 44 15.27 Leakage at arch tube plugs 44 15.28 Screwing up plugs under steam pressure 44 15.29 Reducing steam pressure before remedying defects 44

SECTION 16 RULES FOR WASHING OUT LOCOMOTIVE BOILERS Clause: Page

16.01 Washout record book 45 16.02 Making correct entries 45 16.03 Control of washout men 45 16.04 Responsibility for examining boilers after washing out 45 16.05 Stabling locomotive 46 16.06 Hot water washing out 46 16.07 Cold water washing out 47 16.08 Procedure for washing out a boiler 48 16.09 Washing out foreign locomotives 51 16.10 Filling cold boilers at depots equipped with hot water washout plants 51 16.11 Blowing down boilers 51a 16.12 Greasing joints of man holes, mud doors, inspection openings, screw plugs, cocks, etc. (all types of boilers and unfired pressure vessels) 51a

SECTION 17 STORAGE OF LOCOMOTIVES Clause: Page

17.01 Selection of locomotives for storage 52 17.02 Preparation for storage 52 17.03 Storage of saturated locomotives 55 17.04 Locomotives in storage 55 17.05 Preparation of locomotives for service after storage 55 17.06 Subsequent boiler washout period 56 17.07 Re-treatment of locomotives for continuous storage 56a

SECTION 18 STANDARDISATION OF BOILER RECORDS Clause: Page

18.01 Record books 57 18.02 Instructions for recording 57 18.03 Periodical inspection of records 57

SECTION 19 SPECIAL INSTRUCTIONS FOR THE CARE AND MAINTENANCE OF ALL- STEEL LOCOMOTIVE BOILERS Clause: Page

19.01 Scope 58 19.02 Type of construction 58 19.03 Hydrostatic test periods and pressure 58 19.04 Steam tests for new boilers 59 19.05 Steam tests for existing boilers 59 Department of Railways, New South Wales Boiler Maintenance Regulations Page ix

19.06 Setting of safety valves 59 19.07 Internal examination periods 59 19.08 Internal examinations by Boiler Inspector 60 19.09 Preparation and internal examination 60 19.10 Examination of hollow flexible wall stays at internal examinations60 19.11 Examination and testing of flexible crown stays at internal examinations 62 19.12 Adjustment of nuts on flexible crown stays when tubes are fitted or re- expanded 62 19.13 Examination of exterior of boilers at internal examinations 63 19.14 Removal of lagging sheets 63 19.15 Testing boiler after internal examination 63 19.16 Annual examination 63 19.17 Biennial examination 65 19.18 Special examination and testing of flexible crown stays in ‘D57’, ‘D58’, ‘D59’, and ‘AD60’ class boilers 65 19.19 Monthly examinations 66 19.20 Responsibility for special and monthly crown stay examinations67 19.21 Renewing flexible crown stays at monthly examinations 68 19.22 Broken stays 68 19.23 Reporting stay withdrawals and attention 68 19.24 Maintenance of wall stays 68 19.25 Maintenance of firebox seams and rivets 69 19.26 Corrosion in fireboxes 69 19.27 Monthly examination of smokebox, ashpan and grates 69

SECTION 19 SPECIAL INSTRUCTIONS FOR THE CARE AND MAINTENANCE OF ALL- STEEL LOCOMOTIVE BOILERS (continued) Clause: Page

19.28 Records of monthly examinations 69 19.29 Removal of lagging to detect leaks 69 19.30 Daily examination of fireboxes 70 19.31 Daily examination of smokeboxes 70 19.32 Removal of side lagging sheets for examination of side plates 70 19.33 Washing out boilers 71 19.34 Attention to plugs after boiler washout 71 19.35 Examination and cleaning of water gauge columns 71 19.36 Filling boiler after washout 71 19.37 Changing water in boiler to prevent foaming 72 19.38 Daily blowing down 72 19.39 Attention to fires and prevention of cold air entering fireboxes (see also pages 15 and 28) 72a 19.40 Brick arches 73 19.41 Application and maintenance of flues, boiler tubes and arch tubes 74 19.42 Examination and cleaning of thermic syphons 77a 19.43 Diaphragm defects in thermic syphons 771 19.44 Examination of diaphragms of locomotives in workshops 77c 19.45 Neck fractures in thermic siphons 77c 19.46 Renewing syphon neck 77c Department of Railways, New South Wales Boiler Maintenance Regulations Page x

19.47 Syphon barrel defects 77e 19.48 Syphon body defects 77e 19.49 Part syphon renewals 77e 19.50 Syphon renewals 77f 19.51 Relieving strain in syphon necks 77n 19.52 Cleaning thermic syphons 77n

SECTION 20 SAFETY VALVES Clause: Page

20.01 Safety valve Inspector’s duties 78 20.02 Ramsbottom type valves for locomotives 80 20.03 Repair, adjustment and record of Ramsbottom safety valves at Eveleigh and Cardiff Workshops 80 20.04 Officer responsible for adjustment of valves at Depots 81 20.05 Stamping ferrules or liner plate for Ramsbottom valves 81 20.06 Unauthorised interference with safety valves 81 20.07 Despatch of defective pop safety valves to Eveleigh Workshops for repairs 81 20.08 Correct adjustment of safety valves 82 20.09 Unauthorised increase of working pressure 82 20.10 Testing safety valves at Depots 82 20.11 Sealing pop safety valves 83 20.12 Depot name abbreviations 83 20.13 Issue of safety valve certificates 84 20.14 Issue of pop safety valves 84 20.15 Examination and testing of steam gauges at Depots 84 20.16 Damage to steam pressure gauges in transit 85 20.17 Standard test gauges 85

SECTION 21 REGULATIONS COVERING THE INSPECTION AND REPAIR OF STATIONARY AND PORTABLE BOILERS Clause: Page

21.01 Examination by Boiler Inspectors 87 21.02 Completion of repairs and tests 87 21.03 Filing of reports 88 21.04 Boilers due to examination 88 21.05 Examination for defects at periodical fusible plug inspection 89 21.06 Safety valves, periodical checking of the operation of 89

SECTION 22 MAINTENANCE REGULATIONS FOR STATIONARY AND PORTABLE BOILERS Clause: Page

22.01 Number tablet 90 22.02 Stamping number on boilers 90 22.03 Number tablets for new boilers 90 22.04 Issue of number tablets 90 22.05 Removal of number tablets from condemned boilers 90 Department of Railways, New South Wales Boiler Maintenance Regulations Page xi

22.06 Fusible plug examination periods 90 22.07 Regulations governing attendants of stationary and portable boilers 91 22.08 Regulations governing Contract Pumpers working as Attendants in charge of steam plants 91a 22.09 Removal of lagging for examination of stationary and portable boilers 92 22.10 Lagging on stationary and portable boilers 93 22.11 Time allowance for washing out stationary boilers 93 22.12 Responsibility for safe-working 93 22.13 Maintenance of boilers by Boiler Attendants 93 22.14 Examination periods for stationary and portable boilers 94 22.15 Opportunity for interior inspection at Intermediate Examinations94

SECTION 23 HYDROSTATIC AND STEAM TESTS FOR STATIONARY AND PORTABLE BOILERS Clause: Page

23.01 Hydrostatic tests 95 23.02 Steam tests 95 23.03 Accumulation test for discharge capacity of safety valves 96 22.04 Setting safety valves 96

SECTION 24 EXAMINATION OF BOILERS AND UNFIRED PRESSURE VESSELS HAVING LONGITUDINAL LAP SEAMS Clause: Page

24.01 Cutting test grooves 97 24.02 Examination of test grooves under hydrostatic pressure 97 24.03 Recording positions of test grooves 97 24.04 Provision of labour and equipment for cutting test grooves 98 24.05 Sight holes in lagging and brickwork to permit inspection of test grooves 98 24.06 Regular examination of test grooves by attendant in charge of boilers or unfired pressure vessels 98 24.07 Examination of test grooves when sight holes are not provided 98 24.08 Examination of test grooves at washout periods and fusible plug examinations 99 24.09 Action to be taken when test grooves leak in service 99 24.10 Drilling core holes for further examination of plate 99

SECTION 25 REGULATIONS COVERING THE INSPECTION, REPAIR AND TESTING OF UNFIRED PRESSURE VESSELS Clause: Page

25.01 Scope 100 25.02 Examination by Boiler Inspectors 100 25.03 Completion of repairs and tests 101 25.04 Filing of reports 101 25.05 Vessels due for examination 101 Department of Railways, New South Wales Boiler Maintenance Regulations Page xii

SECTION 25 REGULATIONS COVERING THE INSPECTION, REPAIR AND TESTING OF UNFIRED PRESSURE VESSELS (continued) Clause: Page

25.06 Drainage of air reservoirs 102 25.07 Protection from fire 102 25.08 Test grooves 102 25.09 Numbering and classification of unfired pressure vessels 102 25.10 Number tablets for new pressure vessels 103 25.11 Issue of number tablets 103 25.12 Unregistered vessels 103 25.13 Removal of number tablets from condemned pressure vessels103 25.14 New designs 103 25.15 Examination periods 104 25.16 Local periodical examinations 104 25.17 Safety of vessels 104 25.18 Maintenance of unfired pressure vessels 105 25.19 Location 105 25.20 Hydrostatic tests for vessels of riveted or solid drawn construction 105 25.21 Hydrostatic tests for vessels of welded or brazed construction 105 25.22 Hammer tests on welded vessels 106 25.23 Vessels defective under test 106 25.24 Safety valves – periodical checking of the operation of 106 25.25 Greasing joints of man holes, inspection openings, screwed plugs, cocks, etc. 106

DIAGRAMS IN APPENDIX

Fig. 1 Holes in tubeplates for steel flues and tubes. Fig. 2 Copper ferrules for steel flues and tubes in firebox tubeplates. Fig. 3 Tightening copper ferrules for steel flues and tubes in firebox tubeplates with sectional expander. Fig. 4 Swaged ends of steel boiler tubes – firebox end. Fig. 5 Swaged ends of steel flues – firebox end. Fig. 6 Setting steel flues and tubes in tubeplates with roller expander, prior to flaring, prossering and beading. Fig. 7 Flaring steel tubes. Fig. 8 Prossering steel flues and tubes in firebox tubeplates with sectional expanders. Fig. 9 Method of beading steel flues and tubes. Fig. 10 Method of welding steel flues and tubes in firebox tubeplates. Fig. 11 Plain and beaded steel tubes and flues – smokebox end. Fig. 12 Standard beading tools for steel flues and tubes. Fig. 13 Master gauges for standard beading tools for steel flues and tubes. Fig. 14 Tightening arch tubes in firebox plates with roller expanders. Fig. 15 Flaring tool for arch tubes. Fig. 16 Application of copper ferrules to oversize arch tube holes. Fig. 17 Clamp for holding arch tubes against slippage in setting. Fig. 18 Forming bossed hole for arch tube bushes in copper firebox plates. Fig. 19 Arch tube bush being expanded in copper firebox plates. Fig. 20 Beading arch tube bush in copper firebox plates. Department of Railways, New South Wales Boiler Maintenance Regulations Page xiii

DIAGRAMS IN APPENDIX

Fig. 21 Method of beading arch tubes to copper firebox plates of D50, D53, D55 class standard boilers. Fig. 21a Method of applying arch tubes to copper firebox plates. Fig. 22 Method of applying arch tubes to steel firebox plates. Fig. 23 Arch tube cleaner. Fig. 24 Positions for test grooves and core holes in boilers and unfired pressure vessels having longitudinal lap seams. Fig. 25 Details of test groove and core hole. Fig. 26 Position of pilot hole for core drill. Fig. 27 Arrangement of drilling post and ratchet for drilling core holes. Fig. 28 Forming riveted heads on crown stays. Fig. 29 Re-dressing beaded wall stay heads. Fig. 30 fitting new front tubeplate to existing boiler barrel angle ring. Fig. 31 Effect of heavy caulking on riveted seams. Fig. 32 Cracks in plates at longitudinal lap joints. Fig. 33 Cracks in plates caused by tool marks. Fig. 34 Distortion of rivets due to plates being drifted. Fig. 35 Forming snap headed and rounded countersunk headed rivets. Fig. 36 Forming conical headed rivets. Department of Railways, New South Wales Boiler Maintenance Regulations Page 1

SECTION 1 General Regulations Covering the Inspection and Testing of Locomotive Boilers

1.01 INTERNAL EXAMINATIONS BY BOILER INSPECTORS AND PREPARATION OF BOILERS: Boiler Inspectors shall examine all locomotive boilers due for internal examination or major repairs. For the internal examination, the dome cover, regulator stand pipe, internal steam pipe, lagging sheets, all flues, tubes, arch tubes, mud hole doors, inspection doors, plugs and flexible stay caps shall be removed and the boiler efficiently cleaned in accordance with the requirements of the Boiler Inspector. A careful examination shall then be made for the detection of wastage, cracks, pitting, corrosion and grooving; particular attention shall be paid to lapped seams, edges of plates, curvature of flanges, arch tube sleeves or openings in throat or backplates and other parts where defects most frequently develop. Braces and stays with pin jointed ends shall be examined to see they are taut, the pins are properly secured in place and each detail is in a satisfactory condition to support its proportion of the load. All scale and dirt shall be removed from the caps and sleeves of flexible stays and the gasket and thread shall be thoroughly cleaned before the caps are re-applied. A graphite lubricant (see page 51a) shall be smeared on the threads of the caps each time they are assembled to ensure easy removal. Damaged gaskets shall be replaced by new ones. 1.02 SUBMISSION OF BOILER INSPECTION REPORTS: The Boiler Inspector making an examination of a boiler shall be responsible for: (a) Correctly recording, in duplicate, all particulars required on the proper form (X2819 or X2820) for report upon inspection of locomotive boilers. (b) Directing in writing, on the repair form (X2822), in duplicate, all necessary repairs. (c) Keeping in touch with the progress of the work to see that it is properly done. (d) Certifying as to the satisfactory completion of repairs and tests of the boiler, and endorsing the originals, and their respective copies, of the report upon inspection and the repair form accordingly. (e) Recommending that a certificate be issued to authorise the boiler being placed in service, or, if the boiler is considered unfit for service, recommending that it be condemned or reserved for duty at a reduced pressure. 1.03 SUBMISSION OF ESTIMATES FOR REPAIRS WITH INSPECTION REPORTS: Where boilers require extensive or very costly repairs to put them in a satisfactory condition for service, the Boiler Inspector, after examining the boiler and preparing his report, shall seek the assistance of the Foreman Boilermaker and Costing Clerk to ascertain the total cost of carrying out the repairs. The estimate shall be forwarded to the Boiler Engineer with the inspection and repair forms.

1.04 FILING OF INSPECTION REPORTS: Reports of examinations, crown and wall stay diagrams, repair forms, etc., of each boiler examined, shall be forwarded to the Boiler Engineer, and a copy of each report, ,diagram and repair form shall be forwarded to the workshop or depot concerned. Department of Railways, New South Wales Boiler Maintenance Regulations Page 2

1.05 BOILER HISTORY RECORD: Every locomotive boiler shall have a history record file, which shall be forwarded to each centre at which the boiler may be located for service, repair or storage. The history record shall consist of copies of all reports, diagrams, etc., referring to the boiler, and shall be additional to the file of original reports, etc., held by the Boiler Engineer. The boiler history record shall be coupled with the locomotive history file, being detached only when necessary to facilitate examinations and the execution of repairs, or when the boiler is changed on the locomotive. 1.06 REPAIRS TO BOILERS ON LOCOMOTIVES IN WORKSHOPS: Boilers on locomotives in workshops for light or medium repairs, shall be examined by the Foreman Boilermaker to determine if any repairs are required. If serious defects are disclosed, the Boiler Inspector shall be informed, and he shall direct the action to be taken. 1.07 SUBMISSION OF REPORTS FOR REPAIRS TO BOILERS ON LOCOMOTIVES IN WORKSHOPS: The Foreman Boilermaker making the examination of a boiler undergoing repairs shall submit a typewritten report to the Boiler Engineer, giving full particulars of all repairs carried out and tests conducted. A copy of the report shall be attached to the boiler history record. When the Boiler Inspector is called upon to make the examination, he shall submit the necessary report instead of the Foreman Boilermaker. 1.08 TESTING OF NEW BOILER PLATES: When boiler plates are received from the Manufacturer, they shall be tested by the Testing Engineer, and he shall supply a copy of the test results to the Boiler Engineer. 1.09 MARKING OF PLATE DIAGRAMS FOR NEW OR RE-BUILT BOILERS: A diagram of each boiler being constructed or re-built shall be supplied, in duplicate, to the Boiler Inspector in the workshops, and he shall mark the plate number and tensile test figures of each new plate on the diagram. The diagram shall be forwarded to the Boiler Engineer for filing, and a copy attached to the boiler history record at the workshop. 1.10 INSPECTION OF WORK DURING CONSTRUCTION OF NEW BOILERS: During the construction of new boilers, the Boiler Inspector shall inspect the work at all stages; giving careful attention to the drilling of holes; annealing of dished, flanged or fireworked material; correct application of wall stays; and the absence of welds in steel stays excepting stays manufactured from steel to Departmental Specification No. G.1, and for which authority has been given for ends to be welded. He shall see that the construction, in every respect, conforms with approved practice, and is in conformity with the drawings issued in regard thereto. 1.11 NUMBERING OF NEW BOILERS: Each locomotive boiler, when first constructed, shall be marked with a registered number on the bottom lip of the firehole ring, and on the left hand top corner of the firebox shell backplate just below the longitudinal stays. In addition, a registration plug bearing the number of the boiler shall be fitted in the centre of the shell backplate above the firehole. The registered number shall be issued by the Boiler Engineer. Department of Railways, New South Wales Boiler Maintenance Regulations Page 3

Every boiler shall retain its original registered number throughout its life. 1.12 TESTS ON COMPLETION OF NEW BOILERS: Each new boiler, on completion, shall be subjected to the hydrostatic and steam tests provided for elsewhere in these Regulations. The tests shall be conducted under the supervision, and to the satisfaction of the Boiler Inspector. 1.13 SUBMISSION OF REPORT UPON FIRST INSPECTION OF NEW BOILERS: When the hydrostatic and steam tests on a new boiler have been satisfactorily completed, the Boiler Inspector shall submit a report upon first inspection (X2819), together with the diagrams described in Clause 1.09 to the Boiler Engineer. 1.14 SERVICE CERTIFICATE: Before a new boiler, or an existing boiler repaired after internal examination, is placed in service, a certificate showing that it has satisfactorily passed all tests and is safe for service shall be issued. The certificate shall be issued from the Office of the Boiler Engineer, and will authorise the boiler for a specified term of service. 1.15 CO-OPERATION TO OBTAIN EFFICIENT WORK: These Regulations shall not, in any way, lessen the responsibility of Foremen, Sub- foremen and Leading Boilermakers, when carrying out repairs, etc., in workshops and depots, for detecting and reporting defects that may not have previously been reported. The workshops’ and depots’ staffs concerned shall co-operate with the Boiler Inspector to achieve the best possible results, both in the examination and in the efficiency of the work. SECTION 2 Inspection, Repair and Testing of Locomotive Boilers at Depots

2.01 BOILERS DUE FOR EXAMINATION OR TEST: Steamshed Inspectors shall be advised by Decision Form and Returns Nos. 3, 4 and 6, of boilers due for internal examination, intermediate test and crown stay examination. 2.02 EXAMINATION AND REPAIRS: The Boiler Inspector shall carry out the examination of boilers due for inspection, and show on a repair form (X2822) what repairs are necessary. A copy of the repair form, addressed to the Steamshed Inspector of the district concerned, shall be served upon the Sub-foreman or Leading Boilermaker. When the repairs and hydrostatic test have been satisfactorily completed, the Boiler Inspector shall endorse the repair form to this effect. 2.03 FILING OF REPORTS: After repairs have been completed and tests conducted to the satisfaction of the Boiler Inspector, a copy of the report on subsequent inspection (X2820), together with a copy of the repair form, shall be endorsed and forwarded to the Steamshed Inspector for attaching to the boiler history record. The original copies of the report and repair forms shall be forwarded to the Boiler Engineer. 2.04 SUSPENSION OF CERTIFICATE DURING REPAIRS: When a boiler is stopped for repairs which will take several days to complete, the Boiler Inspector shall endorse the repair form (X2822) to suspend the currency of the Department of Railways, New South Wales Boiler Maintenance Regulations Page 4 certificate during the time the boiler is out of service for repairs. 2.05 STOPPING LOCOMOTIVES FOR BOILER REPAIRS: When a Boiler Inspector has occasion to stop a locomotive for workshop attention, due to some defect in the boiler, he shall direct, on a repair form (X2822) in duplicate, and by altering the printed wording thereon, that the locomotive be sent to the workshops for examination and repairs. The original form shall be forwarded immediately to the Boiler Engineer, and the copy served on the Steamshed Inspector of the district to which the locomotive is allotted. The original form shall subsequently be forwarded by the Boiler Engineer to the Works Manager concerned to be noted. It shall then be sent to the Boiler Inspector in the workshops. On completion of the work, the original repair form, together with all reports in connection with the work, shall be returned to the Boiler Engineer. 2.06 SUBMISSION OF REPORTS ON BOILERS REPAIRED AT DEPOTS AND NOT SUPERVISED BY A BOILER INSPECTOR: When repairs, other than running repairs, are effected at a depot and are not supervised by the Boiler Inspector, a report setting out the nature of the repairs, together with any necessary diagrams, shall be prepared by the Sub-foreman Boilermaker or Officer responsible. The report and diagrams shall be forwarded to the Boiler Engineer, and copies shall be attached to the boiler history record (see Clause 1.05) at the depot. 2.07 BOILER REPAIR BOOK: A boiler repair book (X2885) shall be kept at each depot. It shall show the date and description of all repairs to boilers, and the name of the boilermaker who carries out the work. The boilermaker in charge shall supervise the work and see that correct entries are made. SECTION 3 Hydrostatic and Steam Tests for Locomotive Boilers

3.01 GROUPING FOR TEST PURPOSES: Every locomotive boiler, before being put into service, and at specified periods whilst in service, shall be tested by hydrostatic pressure in the manner described herein. In addition, every new boiler, and every existing boiler after internal examination or heavy repairs to firebox, firebox shell or barrel, shall be tested by steam pressure test subsequent to the hydrostatic test. Locomotive boilers requiring testing, and for the purposes of these tests only, shall be classified in one of the following groups: Group A. New boilers prior to being placed in service. Group B. Boilers, other than new boilers, which have received internal examination or heavy repairs to firebox, firebox shell or barrel, etc. Group C. Boilers, other than new boilers, due for intermediate hydrostatic test at periods between internal examinations. 3.02 HYDROSTATIC TESTS: For boilers in Groups A, B and C, the hydrostatic test shall be made with warm water at a temperature of approximately 150° F. In each boiler being tested, care shall be taken to see that all air has escaped, and that the boiler is completely filled with water. The Department of Railways, New South Wales Boiler Maintenance Regulations Page 5 pressure shall then be steadily applied and when the correct test pressure has been reached, it shall be maintained for a period of 15 minutes. A thorough examination of the boiler shall be made during this period for signs of bulging, cracking, leakage or other defects. Department of Railways, New South Wales Boiler Maintenance Regulations Page 6

Nov, 1944

Hydrostatic and Steam Tests for Locomotive Boilers.

3.03 HYDROSTATIC TEST PRESSURES: The pressures for hydrostatic tests shall be calculated as follows: Group A. Test pressure = Working pressure plus 25 per cent. Group B. Test pressure = Working pressure plus 15 per cent. Group C. Test pressure = Working pressure plus 15 per cent.

The following table gives the necessary test pressures for the several working pressures quoted. For working pressures other than those quoted, the correct hydrostatic test pressure shall be calculated on the basis set out above:

Hydrostatic Test Pressure Working Group A Group B Group C Pressure (Working (Working (Working Pressure) Pressure) Pressure) Plus 25 per Plus 15 per Plus 15 per cent. cent. cent. 120 150 138 138 130 163 150 150 140 175 161 161 150 188 172 172 160 200 184 184 170 212 195 195 180 225 207 207 Department of Railways, New South Wales Boiler Maintenance Regulations Page 7

190 238 218 218 200 250 230 230 245 306 282 282

3.04 HYDROSTATIC TEST WITH MOUNTINGS: Boilers undergoing hydrostatic test, under the supervision of a Boiler Inspector at workshops or depots, but which are not to be subsequently steam tested, shall be tested complete with boiler mountings in position, to ensure that all joints, etc., are free from leaks or other defects. 3.05 VARIATIONS IN PRESSURE DURING HYDROSTATIC TEST: During the period for maintenance of pressure in any hydrostatic test, the test pressure shall not be permitted to vary by more than 5 lb. per sq. in. above or 5 lb. per sq. in. below the test pressure prescribed herein. 3.06 STEAM TEST: The steam test on boilers included in Groups A and B shall be made subsequent to the hydrostatic test, and by each boiler generating its own steam. The pressure shall be raised slowly and uniformly, allowing at least 2-1/2 hours to reach the prescribed test pressure. Group A. The test pressure shall be maintained for 30 minutes, after which steam shall be blown off until the pressure is reduced to the approved working pressure. The working pressure shall be maintained for 60 minutes. During the periods in which the test pressure and the working pressure are maintained, the boiler shall be carefully examined for any signs of leakage or evidence of distress arising from the temperature changes following the variation in the pressure. Group B. The test pressure shall be maintained for 60 minutes, during which the boiler shall be carefully examined for any signs of leakage or evidence of distress. 3.07 STEAM TEST PRESSURES: The pressures for steam tests shall be calculated as follows: Group A. Test pressure=working pressure plus 10 per cent. Group B. Test pressure=working pressure. The following table gives the necessary test pressures for the several working pressures quoted. For working pressures other than those quoted, the correct steam test pressure shall be calculated on the basis set out on page 9:

Steam Test Pressure Group A Group B (Working Working (Equal to Pressure Pressure Working plus 10 per Pressure) cent). 120 132 120 130 143 130 140 154 140 150 165 150 160 176 160 170 187 170 Department of Railways, New South Wales Boiler Maintenance Regulations Page 8

180 198 180 190 209 190 200 220 200 245 270 245

NOTE. Steam tests need not be carried out on boilers Group C, unless conditions or circumstances render such tests necessary. Should a steam test be made, the test pressure shall be as for boilers Group B. 3.08 VARIATIONS IN PRESSURE DURING STEAM TEST: During the period for maintenance of pressure in any steam test, the test pressure shall not be permitted to vary by more than 5 lb. per sq. in. above or 5 lb. per sq. in. below the test pressure prescribed herein. 3.09 SETTING SAFETY VALVES: The safety valves on boilers in Groups A and B shall be adjusted and set in accordance with the requirements of Clause 20.08 after the satisfactory conclusion of the steam tests, and on boilers in Group C, during the first period that the boiler is steamed subsequent to the hydrostatic test.

SECTION 4 Instructions for Examination, Repair and Maintenance of Locomotive Boilers at Depots

4.01 MONTHLY EXAMINATION: District Locomotive Engineers shall be responsible for seeing that the firebox and other parts of each locomotive boiler in their charge are examined personally by the Sub- foreman Boilermaker or Leading Boilermaker each month. It shall be clearly understood that where a Sub-foreman Boilermaker is employed he is the officer who shall personally make the monthly examinations. At depots where no Sub-foreman Boilermaker is employed, the Leading Boilermaker shall personally make the examinations. A permanent record of the monthly examinations shall be maintained at each Depot in the record book (X2883) provided for the purpose. The monthly examination shall be carried out in accordance with the following: (a) After the boiler has been washed out, all stays, the firebox crown plate, and every part of the interior that can be seen through the washout holes shall be examined for wasting and corrosion. The water spaces shall be examined for mud and scale, particularly above and below the firehole and amongst the stays. (b) A careful examination shall be made to detect broken or wasted crown stays, flexible stays and rigid wall stays, bulged or wasted firebox plates between stays, cracks, corrosion, leaks, wasted or defective bolts, studs, inspection and mud doors, handholes, or any other defects. All boiler and arch tube plugs shall be examined for worn or defective threads, also the threaded openings into which they fit. Particular care shall be exercised to detect the presence of wasted, thin, sagged, blocked up or leaky tubes, defective beading or ferrules. (c) The arch tubes shall be carefully examined for defects in accordance with the requirements of Section 15. (d) Rigid wall stays shall be examined. The tell-tale holes shall be tested to see that they are open and free. Tell-tale holes shall not, under any circumstances, be Department of Railways, New South Wales Boiler Maintenance Regulations Page 9 plugged up or hammered over. (e) An examination shall be made of the smokebox, spark arrester, deflector plates, ashpan and grates and their operating gear. The District Locomotive Engineer shall strictly supervise the monthly examinations and make occasional inspections of fireboxes, etc., to ensure that the duties are performed efficiently. 4.02 SUPERVISION OF WORK BY SUB-FOREMAN OR LEADING BOILERMAKER: The Sub-foreman or Leading Boilermaker shall daily enter the firebox of each boiler under repairs, direct the Boilermaker carrying out the repairs as to the details of the work to be done, and inspect the work when completed to ensure that it has been satisfactorily executed. 4.03 DAILY SUPERVISION BY OFFICER-IN-CHARGE: The District Locomotive Engineer or Officer-in-Charge shall confer with the senior hand and direct him daily as to the disposal of the work to the best advantage, and arrange, as far as practicable, for the boiler repairs and engine repairs to be carried out simultaneously. 4.04 REPAIRS AT MONTHLY EXAMINATIONS: Defects located at monthly examinations shall be recorded in the repair book as provided for in Clause 2.07, and immediate attention given to the repairs. If immediate attention is not practicable, the repairs shall be carried out at the earliest opportunity. The record of repairs booked shall be examined at frequent intervals by the Steamshed Inspector or Officer-in-Charge, and he shall take the necessary action to ensure repairs being given early attention. 4.05 REPAIRS FOR BROKEN RIVETS IN COPPER FIREBOXES: Where copper rivets are found broken, they shall be carefully removed so as not to disturb the plates. Copper studs shall then be fitted and the seam chamfered and lightly fullered. 4.06 ATTENTION TO LEAKAGES: Leakages in the firebox and outer shells, at angles around the front tubeplate, boiler plugs, studs and brick arch studs, shall be attended to as soon as possible after being detected. Serious erosion has been found to take place when leakages have been neglected. Employees are warned that plugs and studs shall not be screwed up in a boiler under steam pressure. If a serious leakage occurs, the steam pressure shall be reduced immediately to zero before any attempt to remedy the defect is made. 4.07 FOREIGN MATTER IN BOILERS: Locomotive boilers, after having been repaired at workshops or depots, shall be inspected closely by the Sub-foreman, Leading Boilermaker or other responsible Officer, to detect and have removed any portions or stays, rivets or other foreign matter lodged in the boiler. Whenever a boiler is entered, the opportunity shall be taken to remove any obstruction found lodged between the tubes or in the water spaces, etc. Department of Railways, New South Wales Boiler Maintenance Regulations Page 10

4.08 MONTHLY EXAMINATION OF FIREBOX AND FIREBOX SHELL PLATES: At the monthly examinations of boilers, all washout plugs and doors shall be removed and the firebox and firebox shell plates carefully examined, using torch and reflector, to detect any indication of grooving, pitting or fractures in the flanges and other parts. A record shall be kept of all examinations in the record book (X2883) provided for the purpose. At each intermediate test of the boilers, the clothing plates, washout plugs and doors shall be removed, and for those classes of locomotives where it is possible for the boiler to be entered, the regulator also shall be removed. The plates shall then be carefully examined internally and externally for incipient pitting and surface cracks. Pitting and grooving of boiler plates shall be looked for in those parts where stress conditions are likely to be severe. 4.09 SPECIAL EXAMINATION OF VITAL POSITIONS: In the examination of boilers, special attention shall be paid to those parts where it is known that bending actions occur. 4.10 LUBRICATION OF EXPANSION BRACKETS: The expansion brackets on each side of a boiler shall be kept clean and frequently oiled to permit of free movement for the expansion and contraction of the boiler, and thereby lessen the bending action which is a contributory cause of the development of throatplate fractures. 4.11 PROGRESS OF PITTING AND CORROSION: Where pitting is detected, its progress shall be carefully watched, and, should it persist as a line of pit marks for any distance which is considered dangerous, the matter shall be specially reported. A Boiler Inspector shall then make an examination of the affected area, and direct the action to be taken to restore the boiler to safe working condition. All fractures observed in badly pitted plates shall be reported by the Examining Boilermaker. The date and condition of the plate at any previous examination shall be given. Negligence in reporting badly wasted plates will be seriously regarded. Department of Railways, New South Wales Boiler Maintenance Regulations Page 11

Instructions for Examination, Repair and Maintenance of Locomotive Boilers at Depots.

4.12 BOILER INSPECTOR'S REPORT OF CONDITION OF BOILERS AT DEPOTS: When a Boiler Inspector visits a depot, he shall inspect the fireboxes, smokeboxes, ashpans and other details of all boilers available during his visit. He shall render a return showing the condition of each item to the Boiler Engineer and supply a copy to the District Locomotive Engineer. 4.13 LAX SUPERVISION AND FAULTY OR NEGLECTED REPAIRS: The Boiler Inspector shall submit a report, to the Boiler Engineer, on the conduct of boiler work generally at the Depot. He shall bring any case of lax supervision, or neglected attention to repairs, under the notice of the District Locomotive Engineer, who shall take prompt action to rectify the matter. 4.14 CO-OPERATION TO OBTAIN EFFICIENT WORK: It shall be clearly understood that the Boiler Inspector does not relieve the District Locomotive Engineer of any responsibility in the efficient maintenance of boilers in his charge. The District Locomotive Engineer shall be guided by information or directions given by the Boiler Inspector. It is expected that District Locomotive Engineers and Boiler Inspectors will co-operate and bring about an improvement generally in the maintenance of boilers. 4.15 DAILY EXAMINATION OF FIREBOXES: In addition to the regular monthly examinations, the fireboxes shall be inspected daily after the arrival of the locomotives at the Depot. This examination is to be carried out at the first opportunity when the boiler is out of steam, by the Sub-foreman, Leading Boilermaker or Examining Boilermaker (as the case may be) when on duty, for bulges, cracks, overheating, defective stay-heads, irregularly stopped-up or hammered-over tell-tale holes, leaking seams and any other defects that may have developed. The Department of Railways, New South Wales Boiler Maintenance Regulations Page 12 firebars and ashpan shall also be examined. Leaking. stays, seams or cracks developing in plates around stays, are often evidence of the accumulation of mud or scale, and in giving attention to these defects, the cause shall be looked for and removed. Special attention shall be given to those parts of the firebox where the interior surfaces are difficult to reach with the jet from the washout nozzle. Any indication of overheating shall be investigated immediately. 4.16 DAILY EXAMINATION OF SMOKEBOXES: (a) Spark arresters: The spark arrester netting and plates shall be examined by the Sub-foreman, Leading Boilermaker or Examining Boilermaker daily, to ascertain if any openings exist larger than the mesh of the netting. Any such defects shall be satisfactorily repaired before the locomotive re-enters service, and a careful record of these details shall be kept at the depot. (b) Testing for air leaks: Every smokebox shall be examined for air leaks by the Sub-foreman or a competent man appointed in his stead. With the smokebox door properly fastened, and the blower turned on, a search shall be made with a lighted torch over all joints on the outside of the smokebox, around steam pipes, saddle casting, base of funnel, front ring and door, rivets, bolts, pipe connections, and any defects found shall be repaired immediately. 4.17 SPECIAL EXAMINATION OF FIRE PREVENTION APPLIANCES (During Summer Months) From the 1st October, to the 31st March a special examination shall be made immediately prior to a locomotive leaving the Depot to determine whether the fire prevention appliances are in order and proper running position. This examination shall be made by the Boilermaker when on duty or by the Chargeman or his deputy and the information entered in the X2881 record book as an outgoing record under the appropriate headings. 4.17a EXAMINATION OF BOILERS ON LOCOMOTIVES AWAY FROM HOME DEPOT: When a locomotive belonging to another district arrives at a depot for washing out or any other purpose, the Sub-foreman or Leading Boilermaker shall carry out a similar examination to that which would apply to a home depot locomotive. A report on the examination, disclosing any defects, shall be made to the District Locomotive Engineer of the Depot where the examination is made, and a copy forwarded to the District Locomotive Engineer of the district to which the locomotive is allotted.Original page 15 – April, 1949 4.17b PREVENTION OF COLD AIR ENTERING FIREBOXES: Officers shall exercise every precaution against the admission of cold air to hot fireboxes of locomotives when fires are drawn or banked. Fuelmen and other employees authorised to move locomotives in steam, or whose duty it is to deal with fires or rake out ashpans, shall be instructed in the following: (a) Precautions shall be taken to avoid the admission of cold air to hot fireboxes, and any other action which would be likely to chill the plates or tubes. (b) The least possible use shall be made of the blower during the time the fire is being dealt with. (c) Immediately the fire is drawn or banked in any locomotive firebox, and before the locomotive is moved from the ashpit, the blower shall be shut off and the firehole Department of Railways, New South Wales Boiler Maintenance Regulations Page 13 door and damper doors shall be closed and remain closed during any movement of the locomotive until it is stabled. Officers shall closely observe the handling of locomotives with hot fireboxes, and drawn or banked fires. Suitable action shall be taken with employees who fail to observe the above instructions.

Examination and Maintenance of Water Gauge Columns

4.18 RESPONSIBILITY OF STEAM SIZED INSPECTOR: The Steam Shed Inspector or Officer-in-Charge shall be held responsible for seeing that the following regulations for the examination and maintenance of water gauge columns, copper pipes, etc., are strictly adhered to. 4.19 WATER GAUGE COLUMN STEAM PIPES: Water gauge columns of the type fitted with an independent steam pipe connection between the boiler and the top of the gauge column mounting shall be given periodical attention as follows: Every twelve (12) months coinciding with the annual or biennial examination for all steel boilers, or nearest tone-up interval for other types of boilers: (a) Remove and anneal the steam way connecting pipe and thoroughly examine it, also the union nuts, collars and flanges for defects. Any pipe found with flats, kinks, flaws, fractures, faulty connections, weak or thin area, shall be discarded and replaced by a pipe in satisfactory condition. It is essential that the bore of the pipe be unrestricted. Deposits lodged therein shall be removed. The repairing of steam pipes by brazing on patches or other means either in the body of the pipe or at the junction of the collars or flanges to strengthen flaws, thin areas, or fractures, shall not be permitted. (b) Steam way pipes after having been annealed and examined shall be subjected to an hydrostatic test of 1-1/2 times the working pressure. Whilst under this test pressure, they shall be again examined and if found satisfactory, passed for service. This test shall be carried out on the pipe whilst disconnected from the water gauge column. (c) Examine carefully the top steam pipe connection attached to the firebox casing, and also the waterway connection attached to the firebox back plate. Where either of these is found to be in a defective or wasted condition, they shall be renewed. (d) Examine generally the water gauge columns. Should defects be found they are to be remedied immediately in order to maintain this important mounting in a safe and satisfactory working condition. (e) The District Locomotive Engineer shall appoint a competent mechanic to carry out the duties stated in clauses ‘a’ to ‘d’ and institute a book record showing the date the water gauge column on locomotives are dealt with and tested. This record is to be initialled by the employee who conducts the tests. It shall be the duty of the District Locomotive Engineer or Officer-in-Charge to witness the hydrostatic tests whilst they are being applied to the steam way connecting pipes or, in his absence the Sub-foreman or Leading Fitter. Department of Railways, New South Wales Boiler Maintenance Regulations Page 14

4.20 CLEANING STEAM AND WATER WAY PASSAGES OF WATER GAUGE COLUMNS: At each boiler washout the gunmetal plugs opposite to the ends of steam and water passages in the water gauge mountings shall be removed by the washout man and a 3/8 inch diameter brass rod passed through each passage to remove any obstruction, scale or sediment which may be deposited therein, and cause a false water level. All passages shall be kept clean and free and the gauge cocks tested for satisfactory operating condition. 4.21 MAINTENANCE OF WATER GAUGE COLUMN COCKS: (a) Ordinary Plug Type Cocks. Coincident with the monthly boiler and firebox examination, the gauge cock plugs and test cock spindles shall be removed, thoroughly cleaned, ground in if found necessary, and greased with a graphite lubricant (see page 51a). (b) Asbestos Packed Cocks. On washout days and also at the monthly boiler and firebox examination, all gauge cocks shall be checked for satisfactory operation and condition, and the distance the gland or blank nuts are screwed in. Should the cocks be stiff to operate, the cock plugs are to be removed and greased with a graphite lubricant (see page 51a) and the glands repacked with asbestos fibre. When gauge cocks are found to be in satisfactory working condition, not difficult to operate, and not leaking, there is no need to remove them. In assembling or inspecting water gauge cocks and water gauge drain cocks of the asbestos fibre packed type on locomotives, the gland nuts on the cock spindles and the blank nuts on the opposite end must be screwed home to within the limits between a minimum of 1/8 inch to a maximum of 3/16 inch from the hexagon head on the gland nut (or blank nut) and the shell of the cocks. When thus screwed up, the cocks are to be in a free working condition. It is the duty of a mechanic to remove and repack this type of gauge cock. (c) Restricted Opening Through Cocks. On washout days and also at the monthly boiler and firebox examination, the condition of both plug type and asbestos packed cocks shall be checked for correct alignment of the opening through the cock with the passage ways. When it is not possible to pass a 3/8 inch diameter brass rod through the passage ways with the cock in the open position, due to wear of the plug, or after being ground in, action shall be taken to remedy the defect by removing the plug and filing out the opening in it sufficiently to provide an unrestricted bore, and to allow the brass rod to be easily passed through when again assembled. At each monthly examination of gauge glass columns, the Fitter deputed to carry out this work shall, in addition to continuing to remove the two face plugs for the purpose of testing the water ways leading to the boiler, remove the plug immediately above the top of the gauge glass. A wooden dowel stick, 1/4 inch diameter and from 16 in. to 18 in. in length, shall then be passed right through the gauge glass until it comes to rest in the bottom chamber from which the tray and ball shall have previously been removed, and it must be seen in this position by the Fitter before he is satisfied that the vertical passage ways are unobstructed. Department of Railways, New South Wales Boiler Maintenance Regulations Page 15

SECTION 5

Internal Examination Periods and Service Limits for Locomotive Boilers

5.01 INTERNAL EXAMINATION PERIODS FOR LOCOMOTIVE BOILERS:

Locomotive Boiler Classes First Service Second and Period to Subsequent Internal Service Examination Periods to Time Limit Examinations All classes of Round Top or Belpaire type 6 years 3 years boilers having copper fireboxes and tubes 10, 12, 13, 14, 17, 18, 19, 20, 24, 25, 26, 30, 32, 34, 35, 36, 50 and Standard Classes. All classes of Round Top or Belpaire type 4 years 3 years boilers having all steel fireboxes and tubes. 10, Standard, 35, 36, 38, 57, 58, 59, and 60 Classes. All classes of Round Top or Belpaire type 4½ years 3 years boilers having composite fireboxes, i.e. copper firebox wrapper plates with steel tubes and tubeplates. Standard and C36 Classes.

Examination and Test Periods of Locomotive Boilers.

5.02 FIRST TERM BOILERS OF THE 10, 12, 13, 14, 17, 18, 19, 20, 24, 25, 26, 30, 32, 34, 35, 36 AND STANDARD CLASSES HAVING COPPER FIREBOXES AND TUBES: At the age of three years, boilers shall be due for first intermediate hydrostatic test and examination of boiler and firebox generally; no stays or tubes shall be withdrawn unless directed. At four and one half years the boiler shall be due for second intermediate hydrostatic test, the specified number of crown stays (see Clause 6.05) and four small tubes shall be withdrawn. At six years the boiler shall be due for internal examination. 5.03 SECOND AND SUBSEQUENT TERM BOILERS OF THE 10, 12, 13, 14, 17, 18, 19, 20, 24, 25, 26, 30, 32, 34, 35, 36, 50 AND STANDARD CLASSES HAVING COPPER FIREBOXES AND TUBES: At eighteen months after internal examination boilers shall be due for intermediate hydrostatic test; the specified number of crown stays (see Clause 6.05) and four small tubes shall be withdrawn, except that where a new set of crown stays was fitted at the previous internal examination, no crown stays need be removed, and if a new front tubeplate was fitted at the previous internal examination, no tubes need be withdrawn. At three years the boiler shall be due for internal examination or further time extension in service, as thereupon determined. Department of Railways, New South Wales Boiler Maintenance Regulations Page 16

5.04 FIRST TERM BOILERS OF THE 10, STANDARD, 35, 36, 38, 57, 58, 59 AND 60 CLASSES, HAVING ALL-STEEL FIREBOXES AND TUBES: At the age of two years boilers shall be due for first intermediate hydrostatic test and examination of boiler and firebox generally. Four small tubes shall be withdrawn. At three years boilers shall be due for second intermediate hydrostatic test; the specified number of crown stays (see Clause 6.05) and four small tubes shall be withdrawn. At four years boilers shall be due for internal examination. NOTE. For regulations covering the examination and testing of rigid type crown stays in round top fireboxes, see Clause 6.13.

5.05 SECOND AND SUBSEQUENT TERM BOILERS OF THE 10, STANDARD, 35, 36, 38, 57, 58, 59 AND 60 CLASSES, HAVING ALL-STEEL FIREBOXES AND TUBES: One year after internal examination, boilers shall be due for intermediate hydrostatic test and examination of boiler and firebox generally. The specified number of crown stays (see Clause 6.05) shall be withdrawn except where a new set of crown stays was fitted at the previous internal examination, no crown stays need be removed. No tubes shall be withdrawn, unless for the purpose of removing mud deposits. Two years after internal examination, boilers shall be again due for intermediate hydrostatic test and examination of boiler and firebox generally. The specified number of crown stays (see Clause 6.05) and four small tubes shall be withdrawn, except where a new set of crown stays was fitted at the previous internal examination, no crown stays need be removed. At three years, the boiler shall be due for internal examination or further time extension in service, as thereupon determined. 5.06 FIRST TERM BOILERS OF THE COMPOSITE TYPE HAVING COPPER FIREBOX WRAPPER PLATES WITH STEEL TUBES AND TUBEPLATES. At the age of eighteen months boilers shall be due for the first intermediate hydrostatic test and examination of boiler and firebox, generally. Four small tubes shall be withdrawn. At the age of three years boilers shall be due for the second intermediate hydrostatic test, the specified number of crown stays (see Clause 6.05) and four small tubes shall be withdrawn. At four and one half years of age the boilers shall be due for internal examination. 5.07 SECOND AND SUBSEQUENT TERM BOILERS OF THE COMPOSITE TYPE HAVING COPPER FIREBOX WRAPPER PLATES WITH STEEL TUBES AND TUBEPLATES: At eighteen months after internal examination boilers shall be due for intermediate hydrostatic test. The specified number of crown stays (see Clause 6.05) and four small tubes shall be withdrawn, except that where a new set of crown stays was fitted at the previous internal examination, no crown stays need be removed, and if a new front tubeplate was fitted at the previous internal examination no tubes shall be withdrawn. At three years the boiler shall be due for internal examination or further time extension in service, as thereupon determined. Department of Railways, New South Wales Boiler Maintenance Regulations Page 17

NOTE. For regulations covering the examination and testing of rigid type crown stays in round top fireboxes, see Clause 6.13. 5.08 PREPARATION OF OLD BOILERS FOR INTERNAL EXAMINATION: Before boilers 18 years of age and over are prepared for internal examination in the workshops, a preliminary examination shall be made to determine if the repairs that are obviously necessary are such to warrant a recommendation being made for the condemning of the boiler. The Shop Foreman shall confer with the Boiler Inspector in all such cases, so that in the event of the boiler being recommended for condemnation, the expense which would be incurred by scaling, cleaning, etc., will be avoided. 5.09 RECLAMATION OF USABLE MATERIAL FROM CONDEMNED BOILERS: When boilers, are condemned on account of age or condition and are to be cut up, the tubeplates and any other details, if in good usable condition, shall be reclaimed for the purpose of obtaining further service. Crown Stay Examinations for Locomotive Boilers

6.01 CROWN STAY EXAMINATIONS BY THE BOILER INSPECTOR: Examinations of crown stays at intermediate hydrostatic test periods, as directed by Return No. 6 for Belpaire boilers, and in accordance with the requirements of Clause 6.13 for round top boilers, shall be carried out by the Boiler Inspector at workshops and depots. Steamshed Inspectors shall advise when boilers will be ready for examination, giving at least two days’ notice. 6.02 ISSUE OF MONTHLY LIST OF BOILERS DUE FOR CROWN STAY EXAMINATION: The Boiler Engineer shall prepare a monthly list of boilers due for crown stay withdrawal and examination. The list shall be issued during the month preceding the month for examination. 6.03 CROWN STAY DIAGRAMS: Prior to the withdrawal and examination of crown stays for each boiler concerned, the Boiler Engineer shall mark, in duplicate, a printed diagram showing the stays to be withdrawn. The original copy shall be retained by the Boiler Engineer for reference, and the other copy sent to the Steamshed Inspector of the district to which the locomotive is allotted, and shall be filed on the history record at the depot when the examination is completed. 6.04 METHOD OF INDICATING WITHDRAWN CROWN STAYS: The dates and positions of stays withdrawn shall be marked on the face of the printed diagrams in the manner illustrated by the following example: 6 and 11, 2/R } 11 5 and 12, 3/L } 17 The above indicates that the sixth and eleventh stays in the second row from the right and the fifth and twelfth stays in the third row from the left, were withdrawn in November, 1917. The rows shall be the longitudinal lines of stays and the stays in each row shall be counted from the front end. Department of Railways, New South Wales Boiler Maintenance Regulations Page 18

6.05 NUMBER OF CROWN STAYS TO BE REMOVED FOR EXAMINATION: The minimum number of stays, where required, to be removed at each crown stay examination, is shown hereunder:

Locomotive Boiler Class Crown Stays to be Removed 12, 13, 14, 17, 19, 20, 24, 25, 30 4 32, 34, 35, 36*, 38, 50 Standard 6 *Belpaire type firebox

6.06 REPORTING CROWN STAY WITHDRAWALS AND ATTENTION: All withdrawals of crown stays, and the action taken subsequent thereto, shall be recorded on a crown stay diagram and forwarded to the Boiler Engineer. A copy shall be attached to the history file of the boiler at the depot concerned. 6.07 CORRECT FITTING OF CROWN STAYS: Crown stays shall be of the correct length when fitted and the threads of the stays shall be tight in the plates. In Belpaire boilers, the point ends of the stays shall project through the nuts the correct distance shown on the drawings. 6.08 CUTTING OFF POINTS OF CROWN STAYS IN BELPAIRE BOILERS: The use of an oxy-acetylene torch to cut long points of crown stays is forbidden. This practice damages the threads and necessitates the stays being cut through to be removed for examination, thus destroying stays that could possibly have been refitted. 6.09 EVIDENCE OF DEFECTIVE CROWN STAYS: Stays which have become wasted at the necks, immediately above the crown sheet, can generally be detected by the irregular nature of the scale deposit or heavy incrustation. Special attention shall be given to stays found in this condition to determine the extent of the wastage. 6.10 CLEANING OF CROWN STAYS: Where it is not possible to determine the wastage of crown stays, due to the incrustation of scale, the scale shall be broken away with plain ended brass rods; sharpened points will not stand up to the work. Steel rods shall not be used. 6.11 CONDEMNING DIAMETER OF CROWN STAYS: The condemning diameter for all firebox crown stays shall be 9/16in. and stays shall be removed when or before they are reduced to that size. 6.13 EXAMINATION OF RIGID TYPE CROWN STAYS IN BOILERS WITH ROUND TOP FIREBOXES: Round top fireboxes fitted with rigid type crown stays which screw into the outer firebox shell and are riveted over, are provided with a tell-tale hole at the riveted end of each stay to indicate the existence of fractures. In order to determine definitely the condition of these stays, the steel lagging sheets fitted over the firebox shell plates shall be removed at the monthly boiler and firebox examination, also at the intermediate hydrostatic test period, and the tell-tale holes examined for leakage. Stays showing signs of leakage at the tell-tale holes shall be renewed. In cases where boilers have been fitted with complete new sets of crown stays, the period for this examination shall be extended as follows: Department of Railways, New South Wales Boiler Maintenance Regulations Page 19

1st examination after three months’ service. 2nd examination after six months’ service. 3rd examination after nine months’ service. Thereafter the examinations shall be carried out monthly, as previously stated above. 6.14 PLUGGING TELL-TALE HOLES IN CROWN STAYS: The plugging or hammering over of tell-tale holes in rigid type crown stays in order to reduce or prevent leakage is forbidden. Any person found responsible for carrying out this practice will render himself liable to dismissal. 6.15 BROKEN CROWN STAYS: No boiler shall be allowed in service under steam pressure with one or more broken crown stays.

SECTION 7 Wall Stay Examinations for Locomotive Boilers

7.01 EXAMINATION OF WALL STAYS IN FIREBOXES: Sub-foreman and Leading Boilermakers shall closely inspect, personally, the tell-tale holes in wall stays in the firebox. Whenever the holes are ‘made up’, they shall be drilled out. Where there is any sign of bulging or leakage, due to broken wall stays, or incrustation as the result of leakage, the stay concerned shall be removed. Wall stays with defective heads on the fireside shall also be removed. 7.02 REMOVAL OF CLOTHING SHEETS TO FACILITATE EXAMINATION FOR BROKEN STAYS: The firebox side clothing sheets shall be removed, and the backplate clothing loosened, during each monthly examination of the boiler, and a careful examination shall then be made to detect the existence of broken wall stays in the firebox shell plates. 7.03 IMPORTANCE OF WALL STAY INSPECTIONS: The monthly inspection and testing of wall stays of boilers and the prompt renewal of those found broken shall be one of the most important duties of those responsible for the care and maintenance of boilers. 7.04 BROKEN WALL STAYS IN BOILERS: No boiler shall be allowed to remain in service under steam pressure when more than one wall stay is broken. Where a boiler has one wall stay broken and the leakage from same is serious enough to interfere with normal operations, immediate attention shall be given. If no serious leakage occurs the boiler can continue in service until next out of steam when the stay shall be renewed. 7.05 CLEANING OF TELL-TALE HOLES IN THROAT STAYS WHEN BRICK ARCH IS REMOVED: Each time a brick arch is removed, and before the new arch is put in the tell-tale holes in the throat stays shall be cleaned out to their full depth with a 3/16 in. diameter drill. 7.06 REMOVAL OF SIDE TANKS AND CLOTHING SHEETS FOR WALL STAY EXAMINATIONS: When side tank locomotives are in the workshops for repairs, or are undergoing intermediate tests at depots, the side tanks, in addition to the firebox side clothing Department of Railways, New South Wales Boiler Maintenance Regulations Page 20 sheets, shall be removed to permit a thorough examination of the wall stays. 7.07 SUBMISSION OF WALL STAY DIAGRAMS: Each time an examination of wall stays is made, a wall stay diagram shall be forwarded to the Boiler Engineer. The diagram shall show the location of, and the defects in faulty stays. Broken stays shall be indicated by a circle, stays with broken heads by a square, and cracked or partly broken stays by a broken circle. Before submission, the diagram shall be endorsed to show that all defective stays have been renewed. 7.08 PLUGGING OR HAMMERING OVER TELL-TALE HOLES IN WALL STAYS: The plugging or hammering over of tell-tale holes in wall stays in order to reduce or prevent leakage is forbidden. Any person found responsible for carrying out this practice will render himself liable to dismissal. SECTION 8 Copper Tubeplate Examinations for Locomotive Boilers

8.01 EXAMINATION OF COPPER TUBEPLATES: Special examinations of tubeplates, as directed on Return No. 4, shall be carried out by the Boiler Inspector at workshops and depots. Steamshed Inspectors shall advise when the tubes will be withdrawn and the boilers ready for examination, giving at least two days’ notice. When examining copper tubeplates, care shall be taken to detect the presence of cracks in the bridges between the tube holes. These cracks generally commence on the fireside, and develop gradually from a skin crack to a complete fracture through the plate. Any signs of cracks detected shall be recorded in the remarks column of the monthly examination book (X2883). The attention of the Boiler Inspector shall be drawn to the matter on his next visit to the depot, so that he may direct any necessary repairs. If a bridge is found completely fractured, screwed bushes shall be fitted in the tube holes on either side of the fracture, in accordance with Drawing No. 33937. 8.02 REMOVAL OF TUBES FOR PURPOSE OF INSPECTION: Alternate tubes in the two bottom rows shall be removed from boilers at all intermediate hydrostatic tests, unless exempt by the provisions of Clauses 5.02 to 5.04, or by direction of the Boiler Engineer. While the tubes are out, the condition of the interior surfaces of both tubeplates and the barrel shall be determined, and the thickness of the tubeplates measured. Any mud deposits found lodged between the tubes shall be removed. 8.03 REMOVAL OF ADDITIONAL TUBES FOR PURPOSE OF INSPECTION: Where the Boiler Inspector, in his opinion, considers that more tubes than those provided for in these regulations should be removed, he shall direct their removal. 8.04 REPORT ON TUBEPLATE THICKNESS AND CONDITION: Particulars of the thickness and condition of tubeplates, etc., shall be submitted on the subsequent inspection report form (X2820) to the Boiler Engineer, immediately following each examination. 8.05 INSPECTION OF INTERIOR OF BOILER WHENEVER TUBES ARE REMOVED: Whenever a sufficient number of tubes are removed from a locomotive boiler, during repairs, to enable an examination to be made of the interior of the barrel and sheathing Department of Railways, New South Wales Boiler Maintenance Regulations Page 21 plates, if fitted, such an examination shall be carried out by the Boiler Inspector, and a report submitted covering the condition of the barrel, etc., as found. SECTION 9 Tubes for Locomotive Boilers: Examination, Application and Maintenance

9.01 RECORD OF CHANGED TUBES: A record of all changed tubes, showing the dates fitted, shall be kept in the repair book (X2885) at each depot. A diagram showing the tubes changed shall be forwarded to the Boiler Engineer, and a copy attached to the boiler history record at the depot. 9.02 EXAMINATION OF TUBES: The Leading Boilermaker shall make a thorough examination in the smokebox and firebox of the ends of all tubes to determine if leakage is in evidence. 9.03 MAINTENANCE OF FLUES AND TUBES: (a) Beading which has lifted away from the tubeplate shall be set down again to transmit the heat and prevent burning and wastage. Neglect of this attention will necessitate early driving up or renewal of the flues or tubes. (b) Tubes which have the beading badly wasted or broken away, and which are leaking or liable to leak, or have defective ferrules, shall have the ferrules removed. The tubes shall then be driven up, re-expanded, re-ferruled and re-beaded. If long enough, the tubes shall be driven up at the smokebox end until they are almost flush with the smokebox tubeplate. Short tubes shall be removed. (c) Particular care shall be exercised when expanding tubes to avoid over-rolling and thinning the tube ends, but judicious rolling shall be resorted to where evidence of loose or leaky conditions exists. (d) Re-expanding of loose or leaky flues and tubes shall be carried out carefully in order that those adjacent will not be disturbed. A light rolling of the adjacent flues or tubes is necessary to counteract any possible disturbance. Department of Railways, New South Wales Boiler Maintenance Regulations Page 22

Tubes for Locomotive Boilers: Examination, Application and Maintenance.

9.04 APPLICATION OF TUBE FERRULES: Tubes shall not be tightened in the firebox tubeplate by driving the ferrules up, but the ferrules shall be removed and the tubes expanded. The method of applying tube ferrules shown on Drawing No. 42473, shall be adhered to. A copy of this drawing shall be held at each depot for the guidance of the boilermaking staff. 9.05 USE OF OXY-ACETYLENE TORCHES INSIDE FIREBOXES: When an oxy-acetylene torch is to be used inside a locomotive firebox to cut out tube ferrules, or for other repairs, it shall be lighted outside the firebox. When it is necessary to release gas from a torch, this shall also be done outside the firebox. Tubes shall be blown through or swept prior to any work in the firebox being commenced with an oxy-acetylene torch. During the progress of the work, the smokebox door and firehole door shall be kept open to ensure the best ventilation possible. 9.06 DRIVING UP TUBES: When driving up tubes in locomotive boilers, 14 to 18 tubes in saturated boilers, and 12 to 14 tubes in superheated boilers, shall be selected to act as stays during the progress of the work. The tubes selected shall be distributed in such a manner as to give the best support to the tubeplate; the ferrules shall remain in, and the tubes shall not be closed at the smokebox end. When all other tubes have been driven up, the tubes used as stays shall be similarly dealt with to complete the work. Department of Railways, New South Wales Boiler Maintenance Regulations Page 23

9.07 TESTING AFTER TUBE ATTENTION: After tubes have been renewed or driven up, the boiler shall be hydrostatically tested to ensure that tubes have been properly expanded and that brazed tubes have sound joints. 9.08 PROJECTION OF BOILER TUBES IN SMOKEBOXES: The projection of small copper boiler tubes through the front tubeplate shall be as follows:

Locomotive Boiler Class Projection from Smokebox Tubeplate 12, 13, 14, 17, 18, 19, 20, 1 in. 21, 24, 25, 26, 27 All other classes 2 in.

NOTE. The above does not apply to boilers equipped with steel tubes.

9.09 SAG IN TUBES: At the prescribed periodical examinations of fireboxes and tubeplates, the Officer making the examination shall determine the amount of sag evident in the boiler tubes by sighting through them from either end. For the purpose of obtaining a view through the tubes, advantage should be taken of the use of a light at the far end, and for tubes in positions low down at the brick arch, a mirror may also be employed. Tubes found to be totally blind to the vision, due to the sag, shall be removed and replaced by straight tubes. 9.10 CONDITION OF EXPANDED ENDS OF SAGGED TUBES: Particular attention shall be given to the condition of the ends of sagged tubes, where expanded into the tubeplates. Where there is any indication of looseness, leakage, lifting of the beads, defective ferrules, etc., immediate attention shall be given to eliminate any possibility of failure occuring at that point. 9.11 CLEANING SUPERHEATER AND SMALL TUBES: Flues and tubes shall be examined after each washout or at other times when the boiler is out of steam, and where found blocked or making up they shall be cleaned out. Clinkers forming on the ends of superheater elements shall be removed. It is important that tubes and flues be kept clean in order to obtain efficient steaming results from the boilers. With this objective in view engines running main line passenger services should have, if at all possible, the small tubes blown out after every round trip, but for all classes of locomotives except AD60 class, this cleaning period should not exceed seven days. For the AD60 class the flues and tubes shall be thoroughly cleaned each time the fire has been withdrawn for boiler washout or other cause. SECTION 10 Studs in Locomotive Boilers

10.01 BREAKING OFF STUDS: The practice of deliberately breaking studs off boilers is prohibited. Where studs are to be removed, a stud extractor shall be used. A serious view will be taken of any omission to carry out this instruction. Department of Railways, New South Wales Boiler Maintenance Regulations Page 24

10.02 RESTRICTION ON REMOVAL OF STUDS: Except when it is necessary to remove studs from boilers to enable the boiler to be taken out of the frame, or for purposes of repair, studs shall not be removed, unless one or more of the following conditions obtain: (a) The studs are corroded. (b) The thread on the stud is damaged. (c) The studs leak under steam. (d) The studs are bent. (e) The studs are considered unsafe for further service. SECTION 11 Brick Arch Studs in Locomotive Boilers

11.01 RECONDITIONING BRICK ARCH STUD HOLES FOR SHORT TYPE STUDS: Brick arch stud holes shall be inspected at each internal examination of the boiler. Any holes found greater in diameter than 1-1/16 in. shall be welded and re-tapped to the original diameter of 7/8 in. and a standard size stud fitted. Where a stud hole has been welded once, and would require welding a second time to restore the hole to the correct diameter, the condition of the metal adjacent to the hole shall be examined to determine its suitability for re-welding. Where the condition of the metal is doubtful, an expert opinion shall be obtained before proceeding further with the work. 11.02 OVERSIZE BRICK ARCH STUDS (SHORT TYPE): At depots, oversize studs may be used for replacements up to but not exceeding 1-1/4 in. diameter. If it is desired to use a stud greater than 1-1/4 in. diameter, permission of the Boiler Engineer shall first be obtained. 11.03 SHORT TYPE BRICK ARCH STUDS OUT OF ALIGNMENT, PLUGGED HOLES, PLATE THICKNESS AND CONDITION: Boilers received into the Workshops for internal examination fitted with short type brick arch studs out of alignment shall have the studs restored to their original position. The old holes shall be filled by copper welding or by the approved type of screwed copper plug which is also rivetted over on the water side of the copper plate as an additional safeguard. Any arch stud bushes, defective or incorrect plugs found in the firebox side plates shall be removed and the holes closed as previously stated. When it becomes necessary at depots to renew brick arch studs in firebox side sheets, it shall be the responsibility of the Leading Boilermaker to observe the thickness of the plate and to personally supervise the work to ensure that the holes are tapped with good threads, and that sufficient threads exist in the copper plate to satisfactorily hold the stud. If it is discovered that the copper plate around the brick arch stud hole is generally wasted to such an extent that, by fitting the maximum oversize stud the resulting plate thickness will not give sufficient threads to safely carry the stud, the matter shall be reported to the Boiler Engineer for direction, giving the necessary information, or, if a Boiler Inspector is in the district, particulars shall be reported to him for consideration. Department of Railways, New South Wales Boiler Maintenance Regulations Page 25

11.04 COMBINATION BRICK ARCH STUD AND WALL STAY: In order to overcome the frequent renewal of short type brick arch studs, the consequent enlargement of the tapped hole and the wastage of the plate necessitating re-conditioning by welding and re-tapping, a combined type of brick arch stud and wall stay has been adopted, and is now being applied to boilers. This combination stay fulfils the dual purpose of supporting the side firebox plates and holding up the brick arch. It is manufactured from heat resisting anti corrosion steel and has a tell-tale hole drilled into both the head and beaded ends. A thick monel metal washer is fitted under the head to provide a caulking medium in the event of leakage occurring past the threads. Should it become necessary to renew any of these combined stays below the frame line due to leakage through the tell tale holes, etc., the new stays shall be fitted with steam tight threads on that portion passing through the outer steel casing. SECTION 12 Fusible Plugs for Locomotive Boilers

12.01 FUSIBLE PLUGS Fusible plugs shall be fitted into the firebox crown sheet of all locomotive boilers, to act as a safeguard against excessive damage occurring from a shortness of boiler water. Two distinct types of fusible plugs are available for this purpose and the correct type to use for any class of boiler can readily be determined from the following description: - For boilers having a working pressure of less than 200 lb. per square inch, use tin-filled fusible plugs having a square head. - For boilers having a working pressure of 200 lb. per square inch, and over, use lead-filled fusible plugs having a square head with square aperture. 12.02 EXAMINATION AND RENEWAL: Fusible plugs shall be examined every two (2) weeks and shall be replaced with freshly filled plugs at intervals not exceeding two (2) calendar months. At Depots where no boilermaker is available, this work shall be carried out by the Officer-in-Charge. Fusible plugs removed from boilers shall be forwarded to the Locomotive Works Manager (Country Order Section), Eveleigh. In cases where the washout period of the boiler does not coincide with the fusible plug examination or renewal work, the matter should be submitted to the Boiler Engineer for consideration. 12.03 RETURN OF USED PLUGS AND ORDERING OF NEW STOCK: When fusible plugs are removed they shall be stored in a locked box until forwarded to the Locomotive Works Manager. Consignments of used plugs shall be accompanied by an advice note containing particulars of the plugs returned, and an order on the proper form, for a similar number of replacement plugs. Boxes containing freshly filled plugs shall be kept locked and the plugs issued by a responsible person deputed to perform that duty. A proper record of receipt and issues shall be kept.

Fusible Plugs for Locomotive Boilers.

12.04 REPORTING EXAMINATION AND RENEWAL OF FUSIBLE PLUGS: The dates of examination and renewal of fusible plugs shall be reported on monthly returns (Form X469). Plugs renewed on a given date shall not be shown as examined also on that date. Department of Railways, New South Wales Boiler Maintenance Regulations Page 26

12.05 RENEWAL OF PLUGS IN LOCOMOTIVES LEAVING WORKSHOPS: The fusible plugs shall be renewed in boilers of repaired locomotives before leaving the workshops. 12.06 GRAPHITE LUBRICANT ON THREADS OF PLUGS: The threads of freshly filled fusible plugs shall be coated in the Workshops with a graphite lubricant prior to issue (see page 51a). Plugs shall not be again greased when being inserted in the boiler. 12.07 OIL OR GREASE ON TOPS OF PLUGS: Oil or grease shall not, under any circumstances, be allowed to come in contact with any portion of the fusible plugs above the threads. 12.08 EXAMINATION OF PLUGS FOR DEFECTS: District Locomotive Engineers shall instruct their Sub-foreman and Leading Boilermakers to examine all plugs received at their depots. Any plug that does not conform with the drawing shall be forwarded to the Boiler Engineer with a statement showing when and from where the plug was received. SECTION 13 Damage to Locomotive Boilers Through Shortage of Water or Other Causes

13.01 INSPECTION OF FIREBOXES ON ARRIVAL OF LOCOMOTIVES AT DEPOTS: Immediately after the arrival of a locomotive at a depot, and, if possible, in the presence of the incoming driver, before the locomotive is given up, the Shed Chargeman or other officer deputed shall inspect the firebox carefully for discolouration or evidence of leaks or other defects. Any defects detected shall be reported to the Officer-in-Charge. 13.02 SEALING FIREBOXES WHEN DAMAGE IS SUSPECTED: When there is suspicion that damage to a boiler or firebox, through shortage of water, has occurred, the firehole door, and the water gauge mountings shall be promptly wired and sealed. It shall then be arranged for a Sub-Foreman Boilermaker, where employed, or if not available the Leading Boilermaker, or where neither of these are employed, an ordinary Boilermaker to make a preliminary examination of the firebox by breaking the firebox seal, but only when accompanied by the Officer-in-Charge of the depot or when not available by another responsible departmental officer to act as witness as to the condition of the fusible plugs when withdrawn for inspection. If the fusible plugs have been fused or other damage detected, the fusible plugs shall be replaced in their original position. No wire or other instrument shall be put into the fusible plugs, and the water gauges shall not be interfered with in any way. The firehole door shall then be re-sealed in the presence of the officer and the examining Boilermaker, and the matter reported immediately, by telegram, to the Boiler Engineer requesting the services of a Boiler Inspector. If the fusible plugs are found intact and there is no apparent damage to the firebox the boiler is to be returned to service. 13.03 SEALING FIREHOLE DOORS: Where a padlock is used to secure a firehole door, a lead seal shall be applied also. Department of Railways, New South Wales Boiler Maintenance Regulations Page 27

13.04 DISPLAY OF ‘BOILER EMPTY’ BOARDS: To prevent a fire being started in an empty boiler of a locomotive standing in a depot, a ‘Boiler Empty’ board shall be attached to the boiler, near the firehole immediately a boiler is emptied. 13.05 EXAMINATION OF BOILERS INVOLVED IN ACCIDENTS: When a locomotive has been involved in a derailment, collision, or any accident that could possibly cause damage to the boiler, advice shall be promptly forwarded to the Boiler Engineer, by telegram, giving particulars.The boiler shall not be placed in service again until certified as fit by a Boiler Inspector. SECTION 14 Painting Inside Locomotive Boilers with Bituminous Paint

14.01 REPAIRED BOILERS: If during the preparation of a boiler for internal examination, the inside of the barrel, or any portion thereof, had been scaled down to the metal surface, the area concerned shall be painted on completion of repairs. 14.02 NEW BOILERS: In new boiler construction, the whole of the internal surfaces of the barrel, firebox shell, backplates and throatplates shall be painted. 14.03 APPLICATION OF PAINT: The paint used shall be Laboratory Bituminous Paint No. 14, and in applying it, the following instructions shall be observed: (a) Remove all scale from the area of plate to be painted. (b) Remove any surplus red lead from above the sheathing after the sheathing has been fitted. (c) Remove all traces of oil and grease from the plates before the paint is applied. (d) Apply two coats of paint to the inside surfaces. (e) Apply the paint after all work has been finished so that the coating will not be disturbed by being walked on. (f) Stir the paint thoroughly, as it contains 50 per cent. of solid matter, which settles. (g) Exercise care in handling and applying the paint, as it is inflammable. 14.04 INFLAMMABLE VAPOUR: Employees are warned that the vapour given off during the application of Laboratory Bituminous Paint No. 14 is highly inflammable. Smoking, or the use of naked lights in the vicinity, shall not be permitted. 14.05 WORKING IN ENCLOSED SPACES: When working in an enclosed space, such as a tank or boiler, a jet of compressed air shall be used to ventilate the interior. 14.06 SUPPLIES OF PAINT: Supplies of paint shall be ordered through the Comptroller of Stores, from the Wolli Creek Tar Depot. Department of Railways, New South Wales Boiler Maintenance Regulations Page 28

SECTION 15 Instructions for the Care and Maintenance of Arch Tubes in Locomotive Boilers

15.01 RESPONSIBILITY OF DISTRICT LOCOMOTIVE ENGINEER The District Locomotive Engineer shall be held responsible for the cleanliness and safety of arch tubes in locomotive boilers allotted to his depot. On each occasion, a boiler is washed out, the plugs in the arch tubes shall be removed and the pneumatic tube cleaner inserted from each end and passed through the tubes, to ensure the removal of any scale that may be lodged in the bends of the tubes. In the case of the arch tubes in the C.38 class fireboxes, however, these can only be cleaned by inserting the cleaner from the cab end and passing it down the full length of the tubes. The District Locomotive Engineer shall personally examine the arch tubes at frequent intervals, in order to satisfy himself that the regulations are being observed not only during the day shifts, but at other times when boilers are being washed out and the tubes cleaned. If any obstruction, bulging or fractures in the tubes, or fractures in the sleeves or plates are detected, the locomotive shall be stopped for examination by a Boiler Inspector. A record of all examinations of arch tubes conducted by the District Locomotive Engineer, Sub-foreman, or Leading Boilermaker, shall be kept at the depot. The record shall show the date of, and by whom each examination is made and the condition of the tubes. 15.03 ALTERATION TO CLEANING PERIOD, DUE TO BAD WATER CONDITIONS: If it is necessary (due to bad water conditions) to clean and wash out arch tubes more frequently than once per month, or the usual washout period, the regular boiler washout period shall be decreased accordingly. 15.03 OFFICER TO CARRY OUT EXAMINATION: The Sub-foreman, or Leading Boilermaker, when on duty, shall, on all occasions, examine the arch tubes after they have been cleaned out and before the plugs are re- inserted. If no boilermaker is on duty, the Officer-in-Charge, or the Chargeman, day or night, shall be responsible for seeing that the arch tubes are properly cleaned out. At depots where there is no Chargeman or boilermaker on duty at night time, the Officer-in-Charge of the depot shall be responsible for seeing that the arch tube plugs are removed and the tubes cleaned out. 15.04 PERIODICAL EXAMINATIONS: Arch tubes shall be carefully examined, externally and internally, in accordance with the requirements of Clauses 15.05 and 15.06, for evidence of defects, at least once every four weeks. The examination shall be conducted by the Sub-foreman, Leading Boilermaker, Officer-in-Charge or Steamshed Inspector. 15.05 EXTERIOR EXAMINATION OF ARCH TUBES: The exterior of the arch tubes shall be examined for evidence of bulges, mud-burn, warping, brickwear, grooving, cracks and leaks at ends where the tubes are expanded into the sleeves or plates, and other defects. The alignment of the arch tubes shall be checked by means of the gauge shown on Drawing No. 36958 for standard boilers, and Drawing No. 31599 for ‘57’ class boilers. Department of Railways, New South Wales Boiler Maintenance Regulations Page 29

15.06 INTERNAL EXAMINATION OF ARCH TUBES: The tubes shall be examined internally, after being cleaned by the pneumatic cleaner, for signs of laminations, cracks, blisters or other defects. Particular attention shall be given to the ends of the tubes to see that they are properly flared, have not been cut by the arch tube cleaner, and are free from scale. It is impressed on all ,concerned that the arch tubes shall be maintained in a thoroughly first-class condition. 15.07 ADHERENCE OF CLINKER TO TUBES: If clinker is found adhering to the fireside of the tube, it is an indication that scale or mud exists on the waterside. 15.08 PROJECTION OF FLARED ENDS OF ARCH TUBES NOT FITTED WITH SLEEVES: Arch tubes shall not be permitted to remain in a boiler if the tube projects through the plate less than 3/8 in. into the water space. 15.09 COMPRESSED AIR SUPPLY FOR ARCH TUBE CLEANERS: Compressed air is necessary to operate arch tube cleaners. Depots not equipped with a compressed air service can operate the tube cleaners from the air supply of a locomotive. 15.10 STORAGE OF CLEANERS WHEN NOT IN USE: Arch tube cleaners, when not in use, shall be kept submerged in a bath of kerosene oil. 15.11 LUBRICATING CLEANERS: Before using a cleaner, the kerosene oil shall be blown out and the cleaner lubricated with a good grade of light machine oil. The cleaner shall be lubricated before each cleaning operation. 15.12 EXAMINATION OF CUTTERS, ETC., IN CLEANERS: Cleaners shall be carefully examined before being used to see that the cutters and other parts are in good working order. 15.13 CLEANERS REQUIRING REPAIRS: When cleaners fail to work properly, and need repairs other than the fitting of new cutters, pins or drill heads, they shall be forwarded to the Locomotive Works :Manager, Eveleigh, for the necessary attention. 15.14 OPERATION OF CLEANERS: Washout men shall carry out the operation of arch tube cleaning. To ensure the proper cleaning of tubes, the cleaners shall be slowly worked backwards and forwards until all scale has been removed from the tubes. 15.15 MAINTENANCE OF ARCH TUBES: When an arch tube is found to be leaking, the plugs opposite the ends of the tube shall be removed to ascertain the cause of the leakage. The leakage may be found to be due to scale accumulated on the tube or around the tube bush, a crack in the plate from the edge of the tube hole, or the bush being fractured or loose in the plate or tube. These defects, if found, shall be repaired immediately. If the above defects do not exist, and there is sufficient thickness of tube, the tube shall be made tight by rolling with an arch tube roller expander. If, however, the leaking tube is thin, arrangements shall be made for a Boiler Inspector to examine and report on the advisability of removing it and fitting a new tube. Department of Railways, New South Wales Boiler Maintenance Regulations Page 30

15.16 EXAMINATION FOR BRICK WEAR: Each time bricks are removed, and before a new arch is fitted, the arch tubes shall be examined for evidence of brick wear. If excessive brick wear is detected, arrangements shall be made for a Boiler Inspector to examine and report on the condition of the tubes. 15.17 PROHIBITION OF WELDING: Arch tubes shall not be welded either on the water or fire side, or have new ends welded on. 15.18 APPLICATION OF ARCH TUBES: Arch tubes shall be bent to shape and applied at workshops, except under special circumstances, where approval has been given for tubes to be applied at a depot. 15.19 CUTTING TO LENGTH: Tubes shall be cut to the length obtained by actual measurement of fireboxes. The tube ends shall project into the water space a distance not less than 3/8 in. and not greater than 1/2 in. as shown on appropriate drawing. 15.20 CUTTING AND SQUARING ENDS OF ARCH TUBES: Tubes shall be cut with a parting tool or saw, and the ends made square and smooth. Ragged edges frequently start cracks, which open and extend under working conditions. 15.21 ANNEALING ARCH TUBES: After tubes have been cut to proper length, the ends shall be annealed by heating about 3 in. to 4 in. of the tubes at each end to cherry red, and allowing them to cool in slaked lime or saw dust, or the tubes may be allowed to cool with plates placed against the ends to prevent the passage of air through the tubes. 15.22 PROHIBITION OF COOLING IN WATER: Under no circumstances shall arch tubes be cooled by immersion in water. 15.23 SETTING ARCH TUBES: When arch tubes are placed in position, they shall fit closely in the arch tube bushes or holes, whichever are provided, and be securely fastened at both ends by means of a roller expander (see Fig. 14 in appendix). The setting of the tubes shall be checked by means of a tube gauge. Care shall be taken to ensure the tubes being set at 90 deg to the firebox plates and in line with the bushes, where fitted. After the tubes are set and expanded, the ends shall be properly flared with a flaring tool and then lightly re-rolled. 15.24 REPORTING RENEWALS: When arch tubes are renewed, the number and positions of the tubes removed and the cause of removal shall be reported in writing to the Boiler Engineer. 15.25 OVERSIZE HOLES FOR ARCH TUBES WITHOUT SLEEVES: Elliptical arch tube holes may be reamered to make them round, provided the finished diameter does not exceed the standard diameter by. more than 1/8 in. If it is found that the finished diameter of the hole will exceed this allowance, the matter shall be reported to the Boiler Engineer for direction. When oversize holes are enlarged to the maximum allowable size of 1/8 in. above the standard diameter, and the fitting of copper ferrules has been directed, the ferrules shall Department of Railways, New South Wales Boiler Maintenance Regulations Page 31 be applied as shown in Fig. 16 of the appendix. The tubes shall then be set in position as described in Clause 15.23. 15.26 REPLACING ARCH TUBE PLUGS: Whenever arch tube plugs are removed, at the boiler washout period or at any other time, special care shall be exercised to ensure them being correctly replaced and screwed up tightly. As it is possible that plugs will loosen, due to the effects of heat, the employee responsible for their replacement shall give them a final tightening after the fire has been lit and the boiler warmed up, but before any steam pressure has been raised. 15.27 LEAKAGE AT ARCH TUBE PLUGS: When leakage at arch tube plugs is detected, the plugs shall be attended to on the first occasion the boiler is out of steam. 15.28 SCREWING UP PLUGS UNDER STEAM PRESSURE: Employees are warned that plugs shall not be screwed up in a boiler under steam pressure. 15.29 REDUCING STEAM PRESSURE BEFORE REMEDYING DEFECTS: If serious leakage occurs at arch tube plugs, the steam pressure shall be reduced immediately to zero before any attempt to remedy the defect is made. SECTION 16 Rules for Washing out Locomotive Boilers

16.01 WASHOUT RECORD BOOK: Record books (X2882 and X2880) shall be kept at each depot, and the particulars required in connection with washing out and examination shall be regularly entered by those concerned, in accordance with the instructions on the inside covers of the books. 16.02 MAKING CORRECT ENTRIES: The Chargeman and Sub-foreman or Leading Boilermaker shall be held responsible for making their respective entries in the record books, and for seeing that they are correct and comply with the requirements of the washing out regulations. 16.03 CONTROL OF WASHOUT MEN: Washout men, during the time they are engaged in washing out boilers, shall be under the control of the Chargeman or Officer-in-Charge. It shall be that Officer’s responsibility to see that the correct time has elapsed before washing out is commenced, the instructions for washing out a boiler strictly observed, and correct entries made in the washout record book. 16.04 RESPONSIBILITY FOR EXAMINING BOILERS AFTER WASHING OUT: It is the responsibility of the Sub-foreman or Leading Boilermaker to see that boilers are examined after being washed out. Where boilers are washed out and filled during the hours Boilermakers are not on duty, precluding an examination being made, the Sub- foreman or Leading Boilermaker shall arrange to have the next washout rostered at a time when the boiler can be examined. At depots where no boilermakers are employed, the Officer-in-Charge is responsible for carrying out the examination of boilers after washout. When a boiler is washed out and filled at night time, the subsequent washout shall be arranged so that the boiler can be examined. Department of Railways, New South Wales Boiler Maintenance Regulations Page 32

16.05 STABLING LOCOMOTIVE: After completion of the work at the ashpit (drawing the fire and removing the ashes, etc.) the firehole door and damper doors, if fitted, shall be closed before the locomotive is stabled in the shed. After the locomotive is stabled in the shed, and with at least half a glass of water in the boiler, the steam pressure shall be blown down to zero through the injector steam valves. The Chargeman shall be held responsible for seeing that these conditions have been complied with. 16.06 HOT WATER WASHING OUT: The temperature of the water for hot washing out shall not be less than 150° F. Three hours after steam has been blown down, the boiler shall be emptied through the blow-down cock. While a boiler is being emptied, all plugs and doors shall be loosened. Immediately after the boiler is empty, all remaining plugs and doors shall be removed and washing commenced. At the commencement of hot water washing, the hose pipe shall be drained of any cold water that may be standing in the mains. Cold water entering a hot boiler will cause damage to the plates, and it shall be the Chargeman’s responsibility to see that the correct time has elapsed before the washing out is commenced. In no case shall a boiler be emptied and left standing before being washed out. As soon as the boiler is emptied, the washing out shall be taken in hand at once and completed; this is necessary to prevent the silt hardening in the water spaces and on the plates. In depots equipped with hot water washing out systems, boilers that are to be repaired shall be cooled down first, in accordance with the requirements of Clause 16.07, Paragraph (a), and then washed out with cold water. Boilers to be repaired shall not be washed out with hot water and then left standing, as this will cause contraction of the stays, tubes and riveted seams, etc. All washout plugs and mudhole doors shall be removed for the washing out of a boiler. Boilers that are to be repaired, not necessitating early attention, shall be allowed to cool down before being emptied, and then washed out with cold water to remove the mud deposits. After a boiler has been thoroughly washed out with hot water, it shall be examined immediately and then filled with warm water to prevent chilling. 16.07 COLD WATER WASHING OUT: (a) Boilers required for service under 24 hours or boilers to be repaired, necessitating early attention, shall be cooled down prior to cold water washing out. Five hours after steam is out for ‘C35’, ‘C36’, ‘C38’, ‘D57’, ‘D58’, ‘D59’ and ‘AD60’ class engines, and four hours after steam is out for all other classes of engines, the boiler shall be cooled down in the following way: Remove the top filling plug in the front end of the boiler barrel and insert cold water hose and run in cold water until the boiler shows a full glass of water, then open the blow-down cock so that the level of the water in the boiler will be maintained at a height of not less than half glass. Allow the water to circulate through the boiler until the temperature of the water at the blow-down cock is 110 deg. F. The following times for different classes of engines will serve as a guide: Department of Railways, New South Wales Boiler Maintenance Regulations Page 33

D57 Circulate cold water for 2 hrs. 40 min. C38 . Circulate cold water for 2 hrs. 5 min. AD60 . Circulate cold water for 2 hrs. 0 min. C36 and D59 Classes Circulate cold water for 1 hr. 40 min. C35 Circulate cold water for 1 hr. 25 min. D50 Circulate cold water for 1 hr. 10 min. D53-55 Circulate cold water for 1 hr. 10 min. C32 ...Circulate cold water for 1 hr. 0 min. C30 Circulate cold water for 0 hr. 45 min. Z19 and similar classes Circulate cold water for 0 hr. 35 min.

When the temperature of the water has fallen to 110°F. at the blowdown cock, the circulating water shall be shut off and the boiler allowed to empty. While the boiler is being emptied, all plugs and doors shall be loosened. Washing out the boiler shall be started immediately in accordance with the procedure described in Clause 16.08. (b) Boilers standing out of service for periods exceeding 24 hours, or boilers booked for repairs not required to be emptied under this period of time shall be dealt with as follows: After the engine is stabled in the shed, the steam shall be blown down to zero through the injector steam valves, leaving approximately half a glass of water in the boiler. The boiler shall then be allowed to cool down gradually until required for washing out. In no case shall the boiler be emptied until the temperature of the water has fallen to 110°F., and boilers shall be washed out immediately they have been emptied. 16.08 PROCEDURE FOR WASHING OUT A BOILER: The correct procedure for washing out a boiler is as follows and shall be adhered to: (a) Wash crown plate first; commence at the front plug hole in the side of the boiler and work back, directing the stream of water towards the back plate, using the plug holes in their respective order to the back end, so that no scale or mud will be washed on to the back end of the flues. After washing both sides, wash through the holes in the back plate to thoroughly clean the crown plate.

(b) Where a boiler is fitted with arch tubes, the tubes shall be cleaned by means of the arch tube cleaner before being washed through with water. The formation of scale in arch tubes will cause the metal to become overheated, thereby causing the tubes to bulge and warp, and become dangerous and liable to pull out. Every care shall be taken to see that they are thoroughly cleaned. A locomotive shall not be allowed to leave a depot with dirty arch tubes, and all concerned shall take any necessary action to ensure that this instruction is strictly observed. (c) Next, wash the water space between the backplate and firebox through the holes in the backplate. Wash the side plate water spaces through the side holes opposite the crown plate, and the holes in the casing plate midway between the foundation bar and the crown plate. Be sure that all mud and scale are removed from above and below the firehole, and from the water spaces between the firebox and side casing plates. (d) Next, wash the flues and tubes from holes in the boiler shell, near the back tubeplate, and through holes near the top of the barrel at the front end. (e) Next wash the barrel, commencing at holes in the front tubeplate. Wash the scale and mud towards the throatplate, directing the stream of water against the flues Department of Railways, New South Wales Boiler Maintenance Regulations Page 34 and tubes, and up against the sides, reaching as far as possible in all directions. (f) Next wash up through the mudhole door opening on the bottom of the barrel at the throatplate, cleaning the back end of tubes, the sides of the barrel, and the water spaces between the tubeplate and throatplate. (g) Next wash the water space all around through the side and corner holes at the foundation bar, making sure that all spaces and the foundation bar are free from mud and scale. (h) In boilers fitted with combustion chambers, particular attention shall be given to the combustion chamber plates and stays on which scale and mud shall not be allowed to accumulate.

(i) Make a careful inspection of all spaces with rod and light to make sure that there is no mud or scale lodged amongst the stays. It shall not be assumed, that because the water runs clear, that the boiler is clean. When this is done, the mudhole doors shall be carefully replaced, care being taken to make the joints good, and not to put the plugs in cross-threaded. All plugs shall be greased with a graphite lubricant (see page 51a) before being replaced, and care shall be taken to see that they are tightened properly. (j) Washout nozzles shall be in good condition at the couplings and at the nozzle tip, which shall be round and smooth, so that it will throw a solid stream of water. Washout hose shall be 1-1/2 in. standard size, and its couplings shall be free from leaks. (k) Great care shall be taken in the handling of hoses and nozzles under high pressure. The nozzles selected for the job shall be placed and secured in the plug hole before the water pressure is turned on. Hoses under these pressures are liable to ‘kick’ when the pressure is applied, and if the jet of water is not carefully controlled the force is sufficient to cut out a man’s eye, or do other similar very serious damage (l) Washout men shall efficiently clean away loose scale and sediment from the crown plate and water spaces of the firebox, and between the tubes, where accessible, and from the bottom of the boiler barrel. Particular care shall be taken in boilers fitted with arch tubes to see that these are properly cleaned; a serious view will be taken of any laxity in this regard. (m) Where heavy rains occur in district causing turpid conditions of the water, it will be necessary to pay particular attention to the washing out to ensure the water spaces and firebox plates being cleared of all silt.

16.09 WASHING OUT FOREIGN LOCOMOTIVES: Where the boilers of foreign locomotives are washed out at a depot, advice shall be sent to the depot to which the locomotive belongs, notifying date washed and if examined by a boilermaker, so that the information can be recorded in the home depot’s record book.

6.10 FILLING COLD BOILERS AT DEPOTS EQUIPPED WITH HOT WATER WASHOUT PLANTS: The practice of filling a boiler with hot water at a temperature of approximately 150° F., after it has been washed out with cold water, is definitely prohibited. Where it is necessary to have a locomotive with a cold boiler, under steam early, the following Department of Railways, New South Wales Boiler Maintenance Regulations Page 35 course can be adopted: (a) First, run into the boiler sufficient cold water to fill it up to the level of the intermediate plug holes in the firebox side plates. (b) Cut off the cold water and run in hot water until the correct water level shows in the gauge glass. This action will give a resulting water temperature in the boiler of approximately 100° F. and will allow steam to be raised much sooner than with cold water. It will also prevent undue expansion stresses during the heating period. Under no circumstances shall a cold boiler be forced to raise steam under a period of two hours. In all other cases where a boiler has been washed out with cold water and is not required early, it shall be filled with cold water and the usual period allowed for the lighting of the fire before the steam is required.

16.11BLOWING DOWN BOILERS: Before commencing, and immediately after finishing each trip, and whenever warranted by conditions of operations, boilers shall be blown down through the blowdown cocks in order to reduce the silt deposits and salt concentrations. Boilers of engines, however, that are due for washing out are not to be blown down immediately before or after washout attention. Feed water should not be injected into a boiler just prior to blowing down, unless the water level showing in the water gauge is below half glass level. With the water at not less than half glass level, open the blow-off cock till the water level is reduced to one- quarter glass. Where more than one blow-off cock is fitted, each cock shall be operated in turn for approximately equal periods. After the boiler has been blown down to the level stated, it shall be filled to three-quarter glass level. 16.12 GREASING JOINTS FOR MAN HOLES, MUD DOORS, INSPECTION OPENINGS, SCREWED PLUGS AND COCKS, ETC. (All Types of Boilers and Unfired Pressure Vessels) When making joints or greasing plugs or cocks the following instructions shall be observed: Manholes: Smear gasket and the threads of the door studs with *graphite boiler plug lubricant. Barrel Mud Collector (or Belly Plate): Smear the joint faces and threads of door bolts with *graphite boiler plug lubricant. Mud Hole and Hand Hole Doors: Smear the gasket and threads of door stud with *graphite boiler plug lubricant. Screwed Plugs: Smear threads of plug with *graphite boiler plug lubricant. Fusible Plugs: Smear threads of plugs with *graphite boiler plug lubricant. (NOTE. The threads of fusible plugs for locomotive boilers will be greased prior to issue from workshops). *Graphite boiler plug lubricant is a ready prepared product obtainable from the General Stores on requisition. When this is not available an alternative graphite lubricant shall be prepared by thoroughly mixing in the proportion of one (1) small cupful of powdered Department of Railways, New South Wales Boiler Maintenance Regulations Page 36 graphite to one half pint of black oil, similar to that used in axleboxes.

SECTION 17 Storage of Locomotives

17.01 SELECTION OF LOCOMOTIVES FOR STORAGE: Advice as to locomotives suitable for storage shall be forwarded to Steamshed inspectors concerned. Steamshed Inspectors shall see that locomotives to be placed in storage are in good mechanical condition and have a roadworthy life of six months. They shall preferably be stored immediately after tone-up attention. 17.02 PREPARATION FOR STORAGE: (a) Treatment of Elements: When a superheated locomotive is stopped for storage, the front cylinder covers and valves, and the dome cover and throttle valve shall be removed in order to treat the superheater elements. The elements shall be completely filled with a soda-ash and tannin solution, mixed in the proportion of 6 oz. of soda-ash and 2 oz. of tannin to 45 gallons of water. A mixing tank, consisting of a 45 gallon oil drum, open at the top and with a 1 in. diameter valve and short length of hose attached just above the bottom end of the drum, shall be prepared and temporarily mounted on top of the cab. The end of the hose shall be inserted into the valve opening of the internal steam pipe in the dome, so that the solution may gravitate into the elements through the internal steam pipe. In order to displace any condensate, and to thoroughly treat the elements, 90 gallons of the soda-ash and tannin solution shall be gravitated into the internal steam pipe. The excess solution shall be passed out through the valve chambers. (b) Washing out boiler: All the washout plugs, and the mudhole doors in the firebox and barrel, shall be removed and the boiler thoroughly washed out. Every effort shall be made to remove the scale and mud deposits from the internal surfaces of the boiler. The fusible plugs shall not be removed. (c) Lime treatment of boiler: The boiler, after being washed out, shall be allowed to stand for a sufficient time to drain. Any water remaining at the foundation bar shall be syphoned out and dried up. One pound of Fro-lime shall then be blown into the boiler through the various plug holes and openings in turn, and through the dome, care being exercised during this operation to see that all surfaces are effectively coated; a Rega dusting gun shall be used for the purpose. A 24 pound tin of Fro-lime shall be obtained from the Comptroller of Stores on requisition and kept in stock for use as required. The regulator valve and seating shall then be thoroughly greased and replaced, the dome cover joint remade and the regulator handle pinned in the closed position. All threads in the boiler plug holes shall be greased, the plugs tightly screwed in, and the mudhole doors replaced. The boiler shall be completely closed. On no account shall any plugs or seatings be left off, or steam valves attached to the boiler be left open, as it is imperative to exclude the atmosphere and moisture from contact with the internal surfaces of the boiler. (d) Additional treatment for arch tube boilers: Remove the brick arch carefully and store all serviceable bricks for future use. After the boiler has been washed out and treated with Fro-lime, the arch tubes shall be cleaned internally by the use of a pneumatic arch tube cleaner. The arch tubes shall Department of Railways, New South Wales Boiler Maintenance Regulations Page 37 then be painted internally with Laboratory Bituminous Paint No. 14, using a circular brush attached to the end of the universal joint of the pneumatic tube cleaner. The cleaning cutters shall be removed before the brush is attached. The tube brushes can be obtained from the Locomotive Works Manager, Eveleigh, on Order X640. A periodical inspection at three-monthly intervals shall be made in order to further clean and paint any tubes found developing corrosion.

(e) Treatment of smokebox, and cleaning: The tubes and flues shall be thoroughly cleaned and all cinders and ashes removed from the smokebox, firebox and ashpan. The spark arrester shall be painted with crude oil and the funnel and external surfaces of the smokebox chipped and painted with black engine finish. The smokebox ring joint shall be thoroughly greased and the door left tightened up. A water-proof cover plate shall be securely fastened over the top of the tunnel. (f) Preparation of the engine: The connecting rods shall be removed, and the pistons pulled back on to the back cylinder covers. Any soda-ash and tannin solution remaining in the cylinders, steam chest and passages shall be dried out. The walls of the cylinders and steam chests, and the valves and piston rods shall be greased. The cylinder and steam chest covers shall be replaced, and the pistons pushed completely forward, so that the piston rods will be protected within the cylinders. The gudgeon pins shall be replaced in the cross-heads and the connecting rods greased and placed on the footplate or tender. The big and little end brasses shall be tabbed and stored. A plug consisting of bagging shall be inserted in the blast pipe cap to prevent foreign matter entering the cylinder casting. All bright steel work, such as slide bars, side motion, valve motion, handrails, also cast-iron parts including the cylinders and steam chests, etc., shall be thoroughly greased with anti-rust grease to protect them against the weather conditions.

Sight feed lubricators, driver’s brake valves, steam, air and drifting gauges, water gauge protectors and cab windows shall be removed, tabbed and stored for safe-keeping. The lids of axleboxes (oil lubricated) shall be a good fit. After a locomotive has arrived at the storage point, clean hessian or bagging shall be inserted between the axleboxes and the hub faces of the wheels as a protection against dust. The sandboxes shall be left empty, with the sandbox lids in position. (g) Preparation of the tender: All coal shall be removed from the bunker space, and fire-irons and tools stored. The jacks shall be well greased and left on the tenders. The top of the tank shall be thoroughly cleaned of cinders and the drain holes left free. The bunker space and the top of the tank shall be painted with bitumin. The plug shall be removed from the bottom of the tank, and the tank surfaces thoroughly dried out. The filling hole lid shall be a good fit to prevent the admission of rain water. 17.03 STORAGE OF SATURATED LOCOMOTIVES: These regulations, excepting the removal of the dome cover and connecting rods, shall apply to saturated locomotives. Department of Railways, New South Wales Boiler Maintenance Regulations Page 38

17.04 LOCOMOTIVES IN STORAGE: A weekly inspection shall be made of all locomotives in storage to determine if unauthorised persons have interfered with the engines, boilers or tenders, and to safeguard against deterioration, want of protection against air or moisture, damage or loss through theft. The utilisation of parts of stored locomotives to equip running engines is a very bad practice, and shall be discouraged and eliminated as far as practicable, and shall only be resorted to in cases of extreme urgency. 17.05 PREPARATION OF LOCOMOTIVES FOR SERVICE AFTER STORAGE: (a) Lubrication: Upon a locomotive in storage being required for service, it shall, before being moved from the storage road, have the trimmings removed from the syphon pipes to ensure that the oil-ways are properly primed. (b) Boiler hydrostatic test: Where a locomotive has been standing in storage for a period of six months or more, the boiler shall be subjected to a hydro-static test to the working pressure, and all defects disclosed shall be repaired before the boiler is placed in service. (c) Washing out boiler: In order to remove all traces of Fro-lime previously deposited and any other scale evident, all plugs and mudhole doors in the barrel and firebox shall be removed and the boiler thoroughly washed out with cold water. The fusible plugs shall be renewed, the water and steam ways in water gauges tested, and the cocks greased. All boiler plugs and mudhole doors shall then be replaced, the boiler filled to the correct water level, and steam raised. (d) Preparation of engine: Prior to the raising of steam in the boiler, the valves and pistons shall be removed, and the steam, air and drifting gauges, sight feed lubricator, driver’s brake valve, cab windows and water gauge protectors replaced. When steam has been raised in the boiler and the valves and pistons are removed, the superheater elements and steam chest passages shall be blown out with steam.

The valves and pistons shall then be assembled, the connecting rods, cylinder and steam chest covers replaced, the steam and air auxiliaries, safety valves and gauges shall be tested under steam. The wool packs in axleboxes, and grease blocks, shall be examined and oil cups or cellars thoroughly cleaned out and retrimmed. All the monthly examinations shall be carried out. The plug in the blast pipe, and the cover over the funnel shall be removed and the smokebox, ashpan and grates, etc., examined for any defects. 17.06 SUBSEQUENT BOILER WASHOUT PERIOD: When locomotives have been stored for a period greater than three months, and are subsequently put into service after an initial washout, the second and third washouts shall take place within weekly periods. The fortnightly or greater period, where applicable, shall be resumed after the third washout following the return of the locomotive to service.

17.07 RE-TREATMENT OF LOCOMOTIVES FOR CONTINUOUS STORAGE: At the end of each calendar year, locomotives in permanent storage, and which are to continue in storage for a further term, shall be again treated in accordance with the following instructions: Department of Railways, New South Wales Boiler Maintenance Regulations Page 39

Paragraphs ‘a’, ‘c’ and ‘d’ of clause 17.02 shall be adhered to for the treatment of the superheater elements, boiler shell and arch tubes. Any soda ash and tannin solution remaining in the cylinders, steam chest and passages shall be dried out. The walls of the cylinders and steam chests and the valves and piston rods shall be greased. The cylinder and steam chest covers shall be replaced. All bright steelwork, such as slide bars, side motion, valve motion, handrails, also cast iron parts, including the cylinders and steam chests, etc., shall be thoroughly greased with anti-rust grease to protect them against the weather conditions. Any other attention found necessary to prevent deterioration and to afford protection to the locomotive shall be carried out.

SECTION 18 Standardisation of Boiler Records

18.01 RECORD BOOKS: A standard system of record books has been prepared for the recording of all necessary boiler information at depots. The books shall be used exclusively for the purposes intended. The standard record books available are as follows:

No. Designation of use X Arrival, Departure, Coal Conservation 2880 and Washout Record X Inwards Boiler Examination Record 2881 X Washing out Locomotive Boilers (Arch 2882 Tube examination – Tubes, Arch and Smokebox cleaning) X Monthly Record of Examination of 2883 Locomotive Boilers X Examination and Renewal of Fusible 2881 Plugs X Locomotive Boiler Repair Book 2885

18.02 INSTRUCTIONS FOR RECORDING: Instructions regarding the manner in which the records shall be kept, and the person responsible for making the entries, is printed inside the cover of each book. No departure from these instructions shall be permitted. The name of the depot shall be entered in the space provided in each book and all entries shall be made in ink. The books shall be kept clean, and the records neatly entered. 18.03 PERIODICAL INSPECTION OF RECORDS: Divisional Locomotive Superintendents, Steamshed Inspectors, Officers in charge and Boiler Inspectors, shall periodically examine the records for the purpose of correcting and preventing irregularities in operation and examination, and to see that the records are properly entered in the respective books. Department of Railways, New South Wales Boiler Maintenance Regulations Page 40

SECTION 19 Special Instructions for the Care and Maintenance of All-steel Locomotive Boilers

19.01 SCOPE: These regulations are additional to, and shall be read in conjunction with the general regulations relating to locomotive boilers. 19.02 TYPE OF CONSTRUCTION: In all-steel locomotive boilers, the superheater flues, small tubes, firebox plates and stays are made of steel. 19.03 HYDROSTATIC TEST PERIODS AND PRESSURE: Every boiler, before being placed in service for the first time, and at least every 12 months thereafter whilst in service, and after each internal examination or heavy repair to the firebox or barrel, shall be tested hydrostatically with warm water at a temperature of approximately 150° F. Care shall be taken to see that all air has escaped from the boiler, and that the latter is completely filled with water. The pressure shall then be steadily applied, and when the correct test pressure has been reached (see Clause 3.03) it shall be maintained for a period of 15 minutes. A thorough examination of the boiler shall be made during this period for signs of bulging, cracking, leakage or other defects.

Special Instructions for the Care and Maintenance of All-steel Locomotive Boilers.

19.04 STEAM TESTS FOR NEW BOILERS: Subsequent to the hydrostatic test on new boilers, a steam test shall be made by each boiler generating its own steam, allowing at least 2-1/2 hours to reach the prescribed test pressure (see Clause 3.07). This test pressure shall be maintained for 30 minutes, after which steam shall be blown off until the pressure is reduced to the approved working pressure. The working pressure shall be maintained for 60 minutes. During the periods in which the test pressure and the working pressure are maintained, the boiler shall be carefully examined for any signs or leakage or evidence of distress arising from the temperature changes following the variation in the pressure. 19.05 STEAM TESTS FOR EXISTING BOILERS: After the hydrostatic test has been completed on boilers (other than new boilers) which have received internal examination or heavy repairs to firebox or barrel, a steam test to the approved working pressure shall be made by each boiler generating its own steam, allowing at least 2-1/2 hours to reach the test pressure. The test pressure shall be maintained for 60 minutes, during which period the boiler shall be carefully examined for any signs of leakage or evidence of distress. 19.06 SETTING OF SAFETY VALVES: After the satisfactory conclusion of the steam test, the safety valves shall be adjusted and set in accordance with the requirements of Clause 20.08 herein. The boiler shall then be allowed to cool. 19.07 INTERNAL EXAMINATION PERIODS: Department of Railways, New South Wales Boiler Maintenance Regulations Page 41

The periods for internal examinations of all-steel boilers shall be as defined in Section 5 herein. 19.08 INTERNAL EXAMINATIONS BY BOILER INSPECTOR: Internal examinations shall be carried out by Boiler Inspectors in accordance with these Special Instructions, and the General Regulations relating to locomotive boilers. 19.09 PREPARATION AND INTERNAL EXAMINATION: At internal examinations, the dome cover and regulator stand pipe, lagging sheets, all flues, tubes, arch tubes and flexible stay caps, shall be removed and the boiler thoroughly scaled and cleaned. A careful examination shall then be made for the detection of wastage, cracks, pitting, corrosion and grooving; particular attention shall be paid to lapped seams, edges of plates, curvature of flanges, arch tube sleeves, and other parts where defects most frequently develop. Braces and stays with pin jointed ends shall be examined to see that they are taut, the pins are properly secured in place, and each detail is in a satisfactory condition to support its proportion of the load. All scale and dirt shall be removed from the caps and sleeves of flexible crown stays and wall stays, and the gasket and thread shall be thoroughly cleaned before the caps are re-applied. A graphite lubricant (see page 51a) shall be smeared on the threads of the caps each time they are assembled, to ensure easy removal. Damaged gaskets shall be replaced by new ones. 19.10 EXAMINATION OF HOLLOW FLEXIBLE WALL STAYS AT INTERNAL EXAMINATIONS In order to ascertain whether any of the flexible stays are broken under the ball joint, the Boiler Inspector shall test the stays where the ball head fits into the sleeve, by inserting the point of a special screw-driver (described hereunder) in the slot of the stay head, and exerting a force tending to turn the stay. Sufficient force shall be exerted to ascertain if the stays are fractured, but not to twist unbroken stays. Under no circumstances shall supplementary levers be used on the screw-driver.

Special Instructions for the Care and Maintenance of All-steel Locomotive Boilers.

The screw-driver shall be made ‘T’ shaped, from 5/8 in. diameter steel, with the point shaped to suit the slot in the head of the stay, and the handle not more than 15 in. overall. Hollow flexible wall stays have a tell-tale hole 3/16 in. or 1/4 in. diameter drilled from the firebox end of the stay, and extending through the length of the barrel of the stay and into the head a distance of not less than one-third of the diameter of the head. The tell- tale holes are provided for the purpose of indicating, by the leakage of water or steam, that a stay is fractured or severely wasted. It is imperative that tell-tale holes be kept clean and free of all foreign matter excepting the fireproof porous plugs inserted in the inner ends of the holes as hereinafter described. These holes permit the escape of steam or water from fractured stays. Before a boiler is hydrostatically tested, the tell-tale holes shall be thoroughly cleaned throughout their entire length with a drill as shown on Drawing No. 31841, and then tested with an electric tester provided for the purpose. Before using the electric tester, both contacts should be placed against the firebox plate Department of Railways, New South Wales Boiler Maintenance Regulations Page 42 to ensure that the lamp is in good working order. To test a stay, insert one contact in any convenient stay and insert the testing rod in the tell-tale hole of the stay to be tested until the point reaches the end of the hole. On making contact with the bottom of the hole, the electric circuit is closed and the lamp in the handle of the tester will light, indicating that the tell-tale hole is open for its entire length. If the tester point does not reach the end of the tell-tale hole, the lamp will not light, indicating that an obstruction is present in the tell-tale hole. Obstructions detected in this way shall be removed with a drill. Stays showing water leakage from the tell-tale hole shall be renewed. When the hydrostatic test has been completed, the inner ends of the tell-tale holes in hollow flexible wall stays shall be closed by inserting in the tell-tale hole of each stay a fireproof porous plug of approved material. These plugs will exclude foreign matter, but permit leakage of steam or water if the stay is broken or wasted through. 19.11 EXAMINATION AND TESTING OF FLEXIBLE CROWN STAYS AT INTERNAL EXAMINATIONS: Flexible crown stays of the solid ball end or ball nut type shall be tested for defects, after the caps have been removed, in the following way: (a) Take a round nose chisel and strike the top of the stay, at the ball nut or ball end, blows in four opposite directions. (b) Apply a twist test to the ball end of the stay by means of a screw driver (described at the top of page 61) for solid ball ended stays and by means of a special tool shown on Drawing No. 34960 for stays fitted with ball nuts, so that the stay will break loose or cant if partly fractured or broken. Crown stays found broken or fractured shall be removed. In order to check the condition of rigid crown stays through seatings and the adjustment of new and existing crown stays, a hammer test, as described in Clause 19.19 paragraph (e) shall be carried out whilst the boiler is under hydrostatic test. New crown stays if not ringing true, shall be adjusted at the ball end to give the correct sound.

If an existing flexible crown stay gives a dull tone under the hammer test, but is satisfactory under the chisel and twist test, the stay, if a ball nut type, shall be adjusted by screwing down the ball nut on to the seating of the sleeve until the stay rings true. If the stay cannot be screwed down due to being of the solid ball end type, or has a seized ball nut, the position of the stay shall be marked on a diagram for reference at the monthly hammer tests carried out prior to the next special examination of crown stays, in order to avoid the stay being classed as defective. 19.12 ADJUSTMENT OF NUTS ON FLEXIBLE CROWN STAYS WHEN TUBES ARE FITTED OR RE-EXPANDED: The caps of the flexible crown stays (which may be termed expansion stays) in the three transverse rows at the front end of the crown plate (i.e., nearest to the firebox tubeplate) shall be removed and the nuts adjusted each time a new set of superheater flues and small tubes are applied, and when the complete set of flues and tubes are re- expanded. In new boilers, the caps shall be left off until the tubes have been expanded and the nuts adjusted. Department of Railways, New South Wales Boiler Maintenance Regulations Page 43

19.13 EXAMINATION OF EXTERIOR OF BOILERS AT INTERNAL EXAMINATIONS: When a boiler is being internally examined, the exterior of the boiler shall also be examined. 19.14 REMOVAL OF LAGGING SHEETS: The lagging sheets shall be removed at each internal examination, and at any time there is an indication of leakage behind the lagging. 19.15 TESTING BOILER AFTER INTERNAL EXAMINATION: After the boiler has been internally examined, and all necessary repairs completed to the satisfaction of the Boiler Inspector, it shall be hydrostatically tested and steam tested in accordance with the requirements of Clauses 19.03 and 19.05. When the tests have been satisfactorily completed, the inspection reports in connection with the examination, repair and testing of the boiler, shall be forwarded to the Boiler Engineer for approval and the issue of a service certificate. 19.16 ANNUAL EXAMINATION: Each locomotive boiler, at a period of 12 months after internal or biennial examination, whilst in service, shall be examined in accordance with the following regulations, by a Boiler Inspector: (a) The dome cover and regulator stand pipe shall be removed and the interior of the boiler, stay connections, tubes, barrel and firebox plates and seams, etc., carefully examined. (b) Four small tubes shall be marked by the Boiler Inspector and withdrawn for examination, except in the case of the annual examination of second term boilers as specified in clause 5.05. The thickness of the tubeplates shall also be noted if tubes are removed. (c) The lagging sheets shall be removed from the sides of the firebox, and all tell-tale holes in flexible stays cleaned out and tested with an electric tester, in accordance with the instructions given in Clause 19.10. The Boiler Inspector shall examine the boiler for the detection of broken, partly fractured, or wasted crown stays, flexible stays, or rigid wall stays; bulged firebox plates between stays; cracks, corrosion, leaks, wasted or thin tubes; and any other defects. All flexible crown stays and rigid crown stays in seatings shall be tested in accordance with the instructions covering examination and testing of flexible crown stays at internal examinations, contained in Clause 19.11. In all-steel Belpaire boilers, the specified number of crown stays (see Clause 6.05) shall be removed for examination. (d) The arch tubes shall be carefully examined for defects, in accordance with the requirements of Section 15. (e) Rigid wall stays shall be examined. The tell-tale holes shall be tested to see that they are open and free, in order to determine if they are defective. (f) The smokebox, spark arrester, deflector plates, ashpan and grates, and their operating gear, shall be examined. (g) After the boiler has been completely examined, and all necessary repairs carried out to the satisfaction of the Boiler Inspector, it shall be hydrostatically tested in the manner described in Clause 19.03. (h) When the hydrostatic test has been satisfactorily completed, the inspection reports in connection with the examination, repair and testing of the boiler, shall be Department of Railways, New South Wales Boiler Maintenance Regulations Page 44 forwarded to the Boiler Engineer for approval.

19.17 BI-ENNIAL EXAMINATION: Each locomotive boiler shall be examined and tested by a Boiler Inspector at two-year periods after internal examination whilst in service in accordance with the regulations governing annual examinations (Clause 19.16) and the following: (a) The lagging sheets around the throat plate shall be taken off and the caps on the flexible stay sleeves in the lower half of the combustion chamber, where existing, removed. (b) The caps shall be removed from the sleeves of flexible crown stays not provided with a tell-tale hole extending the full length of the stay and into the ball head. (c) All scale and dirt shall be removed from the caps and sleeves of flexible crown stays and wall stays, and the gasket and thread shall be thoroughly cleaned before the caps are re-applied. A graphite lubricant (see page 51a) shall be smeared on the threads of the caps each time they are assembled to ensure easy removal. Damaged gaskets shall be replaced by new ones. (d) Flexible stays shall be examined and tested in accordance with the instructions covering examinations and testing of flexible wall stays and crown stays at internal examinations, contained in Clauses 19.10 and 19.11. (e) The boiler shall be hydrostatically tested and the reports submitted in the same manner as for annual examinations.

19.18 SPECIAL EXAMINATION AND TESTING OF FLEXIBLE CROWN STAYS IN ‘D57’, ‘D58’, ‘D59’ AND ‘AD60’ CLASS BOILERS: Every twelve months, coinciding with the annual or bi-ennial examinations, the flexible crown stays shall be given a special examination, as herein described, and at each monthly period intermediate between such special examinations, an examination referred to as a monthly examination, as per Clause 19.19 shall be carried out.

The top lagging sheets over the firebox shell shall be removed and the boiler subjected to a hydrostatic test with warm water to a pressure equal to the working pressure. Whilst the boiler is under the test pressure, the examining Boilermaker shall enter the firebox and hammer test the stays by striking two or three blows on the head end of each stay to determine by their sound if any are broken. The caps on the sleeves shall be removed and the stays tested for defects in the following manner: (a) Take a round-nose chisel and strike the top of the stay, at the ball nut or ball end, blows in four opposite directions. (b) Apply a twist test to the ball end of the stay by means of a screw driver (described at the top of page 61) for solid ball ended stays, and by means of a special tool shown on Drawing No. 34960 for stays fitted with ball nuts, so that the stay will break loose or cant if partly fractured or broken. Crown stays found broken or fractured shall be renewed. If an existing flexible crown stay gives a dull tone under the hammer test, but is satisfactory under the chisel and twist test, the stay, if a ball nut type, shall be adjusted by screwing down the ball nut on to the seating of the sleeve until the stay rings true. If Department of Railways, New South Wales Boiler Maintenance Regulations Page 45 the stay cannot be screwed down due to being of the solid ball end type, or has a seized ball nut, the position of the stay shall be marked on a diagram for reference at the monthly hammer tests carried out prior to the next special examination of crown stays in order to avoid the stay being classed as defective. A new diagram indicating sound stays which cannot be screwed down shall be prepared at each subsequent special examination of crown stays. 19.19 MONTHLY EXAMINATIONS: Each locomotive boiler shall be examined at least once every four weeks whilst in service by the Sub-Foreman or Leading Boilermaker, in accordance with the following: (a) A careful examination shall be made to detect broken or wasted crown stays, flexible stays and rigid wall stays; bulged firebox plates between stays; cracks; corrosion; leaks; wasted or thin tubes, and any other defects. (b) The arch tubes shall be carefully examined for defects, in accordance with the requirements of Section 15. (c) After the boiler has been washed out, all stays, the firebox crown plate, and every part of the interior that can be seen through the washout holes, shall be examined for wasting and corrosion. The water spaces shall be examined for mud and scale, particularly above and below the firehole and amongst the stays. (d) Rigid wall stays shall be examined. The tell-tale holes shall be tested to see that they are open and free. Tell-tale holes shall not, under any circumstances, be plugged up or hammered over. (e) Boilers with flexible crown stays not provided with a tell-tale hole extending the full length of the stay and into the ball head shall be subjected to a hydrostatic test with warm water to a pressure equal to the working pressure. Whilst the boiler is under the test pressure, the examining Boilermaker shall enter the firebox and hammer test the crown stays by striking two or three blows on the head end of each stay to determine by their sound if any are broken. If any stays are found broken they shall be renewed. If stays are detected which do not ring true, other than those with seized nuts, or solid ball ends, but known to be sound as determined at the special examination, the lagging sheets and stay caps shall be removed and the ball ends of the stays subjected to the chisel and twist tests described in Clause 19.18, paragraphs (a) and (b). 19.20 RESPONSIBILITY FOR SPECIAL AND MONTHLY CROWN STAY EXAMINATIONS: The Sub-Foreman shall be responsible for the regulations governing the examination and testing of crown stays being properly carried out. No person other than the Sub-Foreman, Leading Boilermaker or Examining Boilermaker, specially trained for the work, shall carry out the hammer testing of crown stays. 19.21 RENEWING FLEXIBLE CROWN STAYS AT MONTHLY EXAMINATIONS: After a new crown stay has been fitted to a boiler, it shall be checked under a hammer test to ensure that the ball nut has been properly adjusted, that the stay rings true, and existing stays adjacent to the new stay are not jut out of their correct adjustment by excessive tightening of the ball nut on the new stay. 19.22 BROKEN STAYS: Broken or partly broken stays shall be renewed immediately. Flexible or rigid stays adjacent to those found broken or defective shall be examined carefully with the object Department of Railways, New South Wales Boiler Maintenance Regulations Page 46 of locating any additional defective stays which, if found, shall be removed. The positions of broken, partly broken or defective stays shall be indicated by means of a circle, broken circle or square respectively, on the diagram form provided for the purpose. 19.23 REPORTING STAY WITHDRAWALS AND ATTENTION: All withdrawals of crown stays and wall stays of the flexible or rigid type, and the action taken subsequent thereto, shall be recorded on a stay diagram and forwarded to the Boiler Engineer. A copy shall be attached to the history file of the boiler at the depot concerned. 19.24 MAINTENANCE OF WALL STAYS: Defective and broken stays shall be drilled out, the holes re-tapped, if necessary, to give a full thread, and new stays fitted. The thread on each new stay shall be examined and, if found defective, the stay shall not be used. Stays shall be screwed into the boiler reasonably tight, and the joint shall project 5/16 in. through the plate. After the stays have been riveted, the tell-tale holes shall be opened up to the full size by means of a drill. A pin drift shall not be used for opening up the tell-tale holes. Under no circumstances shall the heads of wall stays be worked out to a thin edge, as the thin edges tend to curl up under the effects of heat, and give the appearance of stay pulling. The stays shall be worked to maintain, as nearly as possible, a buttonhead appearance. When hammering up leaking stays in the firebox, they shall be held on the outside with a heavy hammer. The riveting of leaking stays shall be done, when practicable, with the boiler empty and warm and, if possible, after standing for a sufficient length of time to dry the scale, as the riveting helps to break away the scale. If stays continue to leak, they shall be replaced by new ones. 19.25 MAINTENANCE OF FIREBOX SEAMS AND RIVETS. When practicable, leaks in the firebox shall be closed by the use of a fullering tool while the boiler is warm. When rivets in firebox seams leak they are either loose or broken. No hammering shall be permitted while there is any steam pressure in the boiler. 19.26 CORROSION IN FIREBOX: Corrosion of firebox plates and rivets at the back bottom corners inside the firebox is brought about by the contact of wet ashes when allowed to remain between the grate and firebox plates, and by leakage of water from under rivet heads. Those concerned shall examine this part of each firebox frequently to observe if leakage or other conditions exist that would corrode the plate and give the necessary attention to prevent further trouble developing. 19.27 MONTHLY EXAMINATION OF SMOKEBOX, ASHPAN AND GRATES An examination shall be made of the smokebox, spark arrester, deflector plates, ashpan and grates, and their operating gear, at each monthly examination of the boiler. 19.28 RECORDS OF MONTHLY EXAMINATIONS: A record of each monthly examination shall be kept at the depot, in the record book (X2883) provided for the purpose. Department of Railways, New South Wales Boiler Maintenance Regulations Page 47

19.29 REMOVAL OF LAGGING TO DETECT LEAKS: If a leak develops under the lagging of a boiler, the lagging shall be removed and the leak located and remedied. The boiler shall be placed in a satisfactory and efficient condition before being returned to service. 19.30 DAILY EXAMINATION OF FIREBOXES: In addition to the regular monthly examinations, fireboxes shall be inspected daily after the arrival of locomotives at the depots, by the Sub-Foreman, Leading Boilermaker or Examining Boilermaker, as the case may be, when on duty, for bulges, cracks, overheating, defective stay heads, irregularly stopped-up or hammered-over tell-tale holes, leaking seams and any other defects that may have developed. The firebars and ashpan shall also be examined. Leaking stays, seams or cracks developing in plates around stays are often evidence of the accumulation of mud or scale, and in giving attention to these defects, the cause shall be looked for and removed. Special attention shall be given to those parts of the firebox where the interior surfaces are difficult to reach with the jet from the washout nozzle. Any indication of overheating shall be investigated immediately. 19.31 DAILY EXAMINATION OF SMOKEBOXES: (a) Spark arresters: The spark arrester netting and plates shall be examined by the Sub-Foreman, Leading Boilermaker or Examining Boilermaker daily, to ascertain if any openings exist larger than that permitted by the standard spark arrester gauge. Any such defects shall be satisfactorily repaired before the locomotive re-enters service, and a careful record of these details shall be kept at the depot. (b) Testing for air leaks: Every smokebox shall be examined for air leaks by the Sub-Foreman or a competent man appointed in his stead. With the smokebox door properly fastened, and the blower turned on, a search shall be made with a lighted torch over all joints on the outside of the smokebox, around steam pipes, saddle casting, base of funnel, front ring and door, rivets, bolts, pipe connections, and any defects found shall be repaired immediately.

19.32 REMOVAL OF SIDE LAGGING SHEETS FOR EXAMINATION OF SIDE PLATES: The side lagging sheets shall be removed from the sides of firebox every six (6) months for the special examination of the side plates. 19.33 WASHING OUT BOILERS: Boilers shall be washed out with either hot or cold water in accordance with the standard instructions for washing out boilers given in Section 16, as often as may be rendered necessary by the quality of the feed water used in the boiler, but not less frequently than once per month. 19.34 ATTENTION TO PLUGS AFTER BOILER WASHOUT: The threads in the plug holes shall be cleaned and examined, and if found to be wasted, shall be re-tapped. The threads of plugs shall be cleaned and smeared with a graphite lubricant (see page 51a) before the plugs are replaced. If a plug is found to be leaking with the boiler under steam pressure, the pressure shall be reduced to zero before any attempt is made to tighten the plug. Department of Railways, New South Wales Boiler Maintenance Regulations Page 48

19.35 EXAMINATION AND MAINTENANCE OF WATER GAUGE COLUMNS: Water gauge columns shall be examined, cleaned, tested and maintained in accordance with the instructions given in Section 4a, pages 15a, 15b and 15c. 19.36 FILLING BOILER AFTER WASHOUT: After the boiler has been thoroughly washed out and inspected, it shall be filled through the top plug hole in the front end of the barrel. For boilers not fitted with a top plug hole in the barrel, the plug hole in the back plate shall be used. Boilers shall not be filled through the blow-down cock under any circumstances. 19.37 CHANGING WATER IN BOILER TO PREVENT FOAMING: It is sometimes necessary, on account of foaming conditions, to change the water in boilers. Before re-filling with cold water, the boiler should be cooled in the same way as for washing out. Where hot water plants are in operation, hot boilers may be refilled with hot water. Blowing down and re-filling a boiler shall not be considered as a washout. Where boilers are to have the water changed at depots equipped with hot water washout plants, the period of three hours shall be allowed to elapse after all the steam has been blown out before the boiler is emptied. The boiler shall then be immediately filled with hot water. 19.38 DAILY BLOWING DOWN: Before commencing, and immediately after finishing each trip, and whenever warranted by conditions of operations, boilers shall be blown down through the blowdown cocks in order to reduce the silt deposits and salt concentrations. Boilers on engines, however, that are due for washing out are not to be blown down immediately before or after washout attention. Feed water should not be injected into a boiler just prior to blowing down, unless the water level showing in the water-gauge is below half glass level. With the water at not less than half glass level, open the blow-off cock till the water level is reduced to one- quarter glass. Where more than one blow-off cock is fitted, each cock shall be operated in turn for approximately equal periods. After the boiler has been blown down to the level stated, it shall be filled to three-quarter glass level. 19.39 ATTENTION TO FIRES AND PREVENTION OF COLD AIR ENTERING FIREBOXES: Officers shall exercise every precaution against the admission of cold air to hot fireboxes of locomotives when fires are drawn or banked. Fuelmen and other employees authorised to move locomotives in steam, or whose duty it is to deal with fires or rake out ashpans, shall be instructed in the following: (a) Precautions shall be taken to avoid the admission of cold air to hot fireboxes, and any other action which would be likely to chill the plates or tubes. (b) The least possible use shall be made of the blower during the time the fire is being dealt with. (c) Immediately the fire is drawn or banked in any locomotive firebox, and before the locomotive is moved from the assist, the blower shall be shut off, and the firehole door and damper doors shall be closed, and remain closed during any movement of the locomotive until it is stabled. Officers shall closely observe the handling of locomotives with hot fireboxes and drawn or banked fires. Suitable action shall be taken with employees concerned who fail to observe the above instructions. Department of Railways, New South Wales Boiler Maintenance Regulations Page 49

19.40 BRICK ARCHES: Brick arches shall be maintained to their full size as shown on the drawings. Worn and broken bricks that are liable to fall shall be renewed. At each washout of the boiler, the arch shall be thoroughly cleaned. At each renewal of the arch, and before it is fitted, the alignment of the arch tubes shall be checked with a gauge, as shown on Drawing No. 36958 for standard arch tube boilers, and Drawing No. 31599 for ‘D57’ class boilers. Arch bricks in this type of boiler are not bonded with fireclay, and to prevent breakage when removing them, care shall be taken not to let them fall. Before an attempt is made to take out the bricks, all slag shall be removed from around the tubes and along the joints of the bricks at the top of the arch. When fitting a new arch, all the bricks shall be carefully fitted to the arch tubes. Special care shall be taken to see that the proper sizes of bricks are used, and that no short bricks are applied. When locomotives are going to the workshops for repairs, the arch bricks shall be carefully removed and stored for further use. 19.41 APPLICATION AND MAINTENANCE OF FLUES, BOILER TUBES AND ARCH TUBES: The following regulations shall be read in conjunction with the diagrams and drawings referred to herein: (a) Setting superheater and small tubes in firebox tubeplate: Care shall be taken to see that the tube holes are true, smooth and free from burrs and sharp edges. Both edges of each hole shall be chamfered to a radius of 1/16 in. as shown in Fig. 1 of the appendix. Holes in old tubeplates shall be made true with a rosebit. Tubes shall be cut to the correct length, annealed at both ends, and have the scale removed before being inserted. Tubes shall be swaged at the firebox end, as shown in Figs. 4 and 5 of the appendix, to a diameter to suit the copper ferrules in which they shall be a driving fit. The type of copper ferrule to be used is shown in Fig. 2 of the appendix, and the method of locating ferrules in the tubeplate by means of a sectional expander is shown in Fig. 3 of the appendix. (b) Application of superheater and small tubes: The tubes shall be placed in the boiler so that the swaged ends project into the firebox 1/4 in. This projection shall be set by means of a gauge to ensure all tubes being uniform. In placing the tubes in the boiler, care shall be taken not to damage the copper ferrules. When the tubes are set in position, they shall be secured tightly in the firebox tubeplate by means of an air-driven roller expander, as shown in Fig. 6 of the appendix. After they have been expanded, the ends shall be flared, as shown in Fig. 7 of the appendix, and the tubes prossered with a standard sectional expander, as shown in Fig. 8 of the appendix. The sectional expander shall be driven up tight with a suitable pneumatic hammer having a 6 in. piston stroke, then slackened back and turned in the tube, half the width of a section, and re-driven, at least three times, or until the tubes are properly set and evenly expanded all the way round. After the tubes have been prossered they shall be beaded with the standard beading tool illustrated in Fig. 12 of the appendix. Care shall be exercised when beading tubes to avoid marking the tubeplate with the beading tool, which shall be held at an angle as shown in Fig. 9 of the appendix. Copper ferrules shall not be allowed to project under beads. Department of Railways, New South Wales Boiler Maintenance Regulations Page 50

Superheater tubes shall be re-rolled after being prossered and before being beaded. (c) Welding superheater and small tubes in firebox tubeplate: The electric welding process only shall be used in welding flues and tubes to the firebox tubeplate. After being properly prossered, expanded and beaded, the boiler is to be tested, and any tubes found showing signs of leakage are to be re-expanded and re-beaded. Subsequent to the completion of the boiler test, the tubes and the tubeplate should be thoroughly cleaned by sand blast or a wire brush to remove all grease, oil and dirt, after which the tube beading shall be seal-welded. Before commencing welding, the boiler shall be filled with warm water at a temperature of 100° F., to a level above the top row of tubes. The work shall be carried out in the following manner: Begin at the top row of tubes and weld each tube in succession across the row; then take the next row down and so on until finished. Start the weld at the bottom of each tube and follow up on one side to the top. Then return to the bottom and weld up on the opposite side, just overlapping the previous weld to overcome any blow or pin holes. Use electrodes of approved grade, No. 8 to 10 gauge, for the superheated flues, and No. 12 gauge for the small tubes. Any deposits of metal formed on adjacent beads while welding shall be removed with a wire brush. A tube with welded bead is illustrated in Fig. 10 of the appendix. (d) Fixing superheater and small tubes in front tubeplate: Tube holes shall be drilled, carefully cleaned and chamfered to a radius of 1/16 in. on the outside edge, and have all burrs removed (See Fig. 1 of the appendix). Tubes required to be beaded shall project through the tubeplate 1/4 in., and those not to be beaded 3/8 in. (see Fig. 11 of the appendix). The tubes shall be expanded into the tubeplate with a standard self-feeding roller expander (shown in Fig. 6 of the appendix) driven by an air machine. After the hydrostatic test, the superheater flues, the small tubes between them, and the first row of small tubes around the flues shall be flared as shown in Fig. 7 of the appendix and beaded with standard beading tools. (e) Leaking tubes: Leaking tubes are frequently caused by overheating, due mainly to a film of scale or mud having formed on the tube and against the tubeplate. This deposit of mud or scale prevents the free convection of the heat, thereby causing the tubes to become overheated and expand more than the plate after cooling to the same temperature as the plate, the tendency is for the tubes to contract to a slightly less diameter than the tube holes. The continual recurrence of this action gradually loosens the tubes in the plate and causes them to leak and the beads to split. The remedy, therefore, is to remove the scale; this can be done by means of a sectional expander, which breaks and dislodges it. Tubes shall be carefully examined for any sign of leakage at each washout and whenever the fire is withdrawn. If leakage is found, the tubes shall be carefully expanded with the sectional expander. If the beading lifts off the plate, the tube shall be re-beaded with a standard beading tool, care being taken not to mark the tube plate. Tubes shall be expanded, where practicable, when the boiler is empty and warm; this tends to loosen all the scale and break it away from the tubeplate, and, also, reduces to Department of Railways, New South Wales Boiler Maintenance Regulations Page 51 a minimum the tendency to split the tubes while being expanded. The sectional expander shall always be kept well oiled. If this is not done the mandrel will become very tight after being driven in, and require excessive hammering on the sides to release it. The practice of hammering to release expanders has been found to be one of the principal causes of old tubes bursting and cracking. When a tube leaks it is usually because it is loose in the tubeplate. The beading tool will not tighten the tube where it is loose. Constant use of the beading tool has the effect of grooving the tubeplate, and it should, therefore, be very sparingly used, and then only when the bead stands off from the plate. (f) Welding leaking superheater and small tubes: When it is found that a tube or a number of tubes which have been welded in the firebox tubeplate are continually leaking, and cannot be tightened by expanding lightly with a sectional expander, the old weld shall be chipped off and the tubes expanded, re-beaded and re-welded. When tubes that have been welded leak slightly, they shall be lightly expanded with a sectional expander. The leaking weld may be lightly caulked with a roughing tool. Where it is necessary to expand tubes which have already been welded, a special sectional expander shall be used which has sufficient clearance to prevent it making contact with the bead. (g) Application and Maintenance of arch tubes: The application and maintenance of arch tubes and bushes shall be carried out in accordance with the requirements of Section 15, and as illustrated in the diagrams of the appendix.

THE MAINTENANCE, REPAIR AND RENEWAL OF THERMIC SYPHONS IN STEEL FIREBOXES.

19.42 EXAMINATION AND CLEANING: Thermic syphons shall be examined both internally and externally after all washouts and also at the monthly examination of the boiler for the detection of cracks, broken stays, mud burns, mud or scale deposits or other defects. It is essential that they be kept clean at all times. Should any of the foregoing defects be observed action shall be taken to remedy the position without delay. The District Locomotive Engineer shall be held responsible for the cleanliness and safety of Thermic syphons in boilers of all locomotives allotted to his depot. The Sub-Foreman, Leading Boilermaker or his deputy when on duty, shall on all occasions, examine the syphons after they have been washed out. If no boilermaker is on duty, the Officer-in-Charge or the Chargeman, day or night, shall be held responsible for seeing that the syphons are properly cleaned after washout. At depots where there is no Chargeman or Boilermaker on duty at night time, the Officer-in-Charge of the Depot shall be held responsible for seeing that the syphons are properly cleaned out after washout before the locomotive is allowed into service. 19.43 DIAPHRAGM DEFECTS: Fractures usually develop in the lower half of firebox diaphragms, as shown in Fig. 1. When such fractures occur they should be bevelled and welded. This repair will usually render satisfactory service for a considerable length of time, but if further fractures develop the diaphragm should be renewed entirely as shown in Fig. 2. This work should preferably be carried out during a classified shopping but in cases of necessity may be undertaken during the time the locomotive is stopped for Tone-up or other light repairs at the depot. Department of Railways, New South Wales Boiler Maintenance Regulations Page 52

19.44 EXAMINATION OF DIAPHRAGMS OF LOCOMOTIVES IN WORKSHOPS. During the time a locomotive fitted with syphons is in the workshops undergoing annual, bi-ennial or other classified repairs, the water side of the diaphragms shall be inspected to determine their condition and if repairs or renewals are necessary. All diaphragms show checks on the water side after service, and mild checks may not indicate that renewal is necessary. As inspection of the water side must be made through the washout hole in the throat plate, the surface of the diaphragm, should be made perfectly clean for accurate conclusion as to the condition of the diaphragm. If checks are deep, indicating early fracture, consideration should be given to renewal while in the shops, thereby avoiding the possibility of fracture occurring soon after the locomotive is returned to service. It is desirable to maintain diaphragms in good condition by making repairs of a permanent nature at the proper time, thus avoiding withdrawal of a locomotive from service. 19.45 NECK FRACTURES: Due to the movement of the firebox plates under working conditions a stress is produced in the syphon neck which eventually produces a fracture as shown by Fig. 3. Such fractures are usually progressive, starting with a short crack on top of the neck principally brought on under the previously mentioned stress conditions by sudden temperature changes due to severe terminal handling. To repair this defect, the fracture is chipped out and welded as shown by Fig. 4. This work can be quite easily carried out in a depot, provided the necessary welding facilities are available. Department of Railways, New South Wales Boiler Maintenance Regulations Page 53

19.46 RENEWING SYPHON NECK: It will be found that in time other adjacent neck fractures will appear and require repairing in the manner mentioned previously. After from four to six such neck welds have been applied it will be necessary to renew the syphon neck at the next classified shopping as shown by Fig. 5. When renewing syphon necks the physical condition of the diaphragm should be considered and if necessary renewed at the same time.

19.47 SYPHON BARREL DEFECTS: In isolated cases portion of the syphon barrel deteriorates or is damaged due to the application of high temperatures in the presence of scale or the accumulation of borings carried up into the barrel by the water circulation. This may occur in the locations indicated in Fig. 6. If a pocket thus formed does not exceed one inch in depth, it may usually be laid up hot with a hammer. In other cases, fire checks as shown develop on the fireside and eventually a transverse crack will appear which may be chipped out and welded up as a temporary repair. It is preferable, however, to apply instead a barrel patch as shown in Fig. 7. This patch should be long enough to replace all the defective area of the barrel. It extends up into the stayed area for reinforcement. Laminations appearing in the syphon barrel may also be repaired by application of the same patch if in that area or by larger syphon sections as shown in subsequent figures. Department of Railways, New South Wales Boiler Maintenance Regulations Page 54

19.48 SYPHON BODY DEFECTS: Failures of vertical welds in the front or back of the water leg are repaired by chipping and re-welding which usually corrects the defects. Transverse fractures in the same area, also fractures in the flange can be similarly repaired. If further repairs, however, become necessary in these locations patches as shown by Figs. 8, 9, 10 and 11 should be applied. 19.49 PART SYPHON RENEWALS: When the necessity of repairing a cracked neck, and a barrel defect occurs at the same time, consideration should be given to the application of a half syphon instead of applying neck and barrel patches. The renewal of major portions of the syphons as shown by Figs. 12 and 13 is generally governed by the physical condition of the plates in the lower sections of the syphon as found during classified overhauls. 19.50 SYPHON RENEWALS: The renewal of an entire syphon depends on the physical condition of the syphon and the firebox sheets generally and each case should be considered individually. The procedure to be adopted when installing syphons is as follows: First of all it is necessary to prepare the openings in the crown sheet and syphon flanges so that they fit correctly and are properly bevelled for welding in accordance with Fig. 14. The syphon is then temporarily fitted into the firebox and bolted into position in order to determine how much of the surplus stock at the end of the syphon neck where it projects into the diaphragm flange should be cut off. When this has been determined the syphon is partially removed and the excess metal cut off, after which the syphon is restored to its proper position in the firebox. The flanges are then securely clamped and bolted to the crown sheet so that when the syphon is in its correct position the neck is centrally located in the diaphragm flange leaving the same clearance all around as shown by Fig. 14. If a new diaphragm is being fitted at this time it should be clamped into position ready for welding, before the syphon has been finally located. Proceed to weld the top flange of syphon to the crown sheet leaving the neck free to move about in the diaphragm flange. Any method of welding syphons to the crown sheet that will properly provide for expansion and prevent creeping as the welding progresses is satisfactory. The back step method shown in Fig. 14 is an example of how this result can be achieved. If a new diaphragm has been fitted it should next be butt welded to the tube sheet. The final operation being to heat and lay up the diaphragm flange to the syphon neck and weld as shown in Fig. 14. Before laying up the diaphragm flange, however, it must be seen that an equal clearance exists all around between the syphon neck and diaphragm flange to prevent undue strains being locked up in the neck after it has been welded to the diaphragm flange. Department of Railways, New South Wales Boiler Maintenance Regulations Page 55 Department of Railways, New South Wales Boiler Maintenance Regulations Page 56 Department of Railways, New South Wales Boiler Maintenance Regulations Page 57 Department of Railways, New South Wales Boiler Maintenance Regulations Page 58

19.51 RELIEVING STRAIN IN SYPHON NECKS: After either a new boiler or a new firebox equipped with syphons has been in service from sixty to ninety days, also at every Annual, Bi-ennial, Time Limit examination or heavy overhaul of an existing boiler so fitted, the strain shall be removed from the syphon neck by the following procedure: (a) After the boiler has been cooled down, washed out and emptied, the neck of each syphon shall be disconnected from the diaphragm flange by chipping or burning off the weld until it is free. Before releasing the flange, however, screwed spreaders should be used to keep the syphons in their correct position. (b) Heat the top half of the diaphragm flange by oxy acetylene torch until it is a medium red heat and by inserting wedges raise the flange to provide a clearance of one quarter of an inch at the top between the flange and syphon neck, tapering off down to the centre. This will allow the neck to rise thereby relieving the strain. A very small vertical adjustment of the diaphragm justifies the relief of the neck strain. (c) Heat and lay up the diaphragm flange starting at the bottom and working up both sides to the top ensuring a good fit of the flange against the syphon neck. When completed weld the flange to the syphon neck. 19.52 CLEANING THERMIC SYPHONS: (a) Syphons fitted to locomotive boilers require definite attention to the details of cleaning operations in order to maintain them in a safe and satisfactory condition and to prolong the life of the device. In bad water territory more attention is required than when feed water is without scale. New syphon equipped boilers and existing boilers equipped with new fireboxes or given heavy repairs should be carefully cleaned before being placed in service. Borings and Department of Railways, New South Wales Boiler Maintenance Regulations Page 59 foreign matter of all kinds shall be removed from a boiler as far as possible before the firing up test. The boiler should be subjected to repeated thorough washing until it is clean. After the firing up test the interior of the syphons shall be inspected to detect and remove deposits that may have accumulated in the syphon barrel. The principal cause of trouble from this source occurs when fine steel borings left in the boiler after tapping and reaming holes are drawn into the syphon from the boiler barrel and throat by the rapid syphon-induced circulation when a boiler is fired. As the velocity of the water is reduced after passing through the syphon neck by reason of the larger area of the syphon body, the circulation is not sufficient to carry the heavy borings out over the crown sheet. The borings are, therefore, deposited just back of the syphon neck as shown in Fig. 6 sometimes to a depth of one inch and from four to six inches across. If allowed to remain the borings will cause overheating and pocketing of the syphon barrel. Syphons shall be thoroughly washed out and cleaned at the time the boiler is being washed out. Washout and inspection holes are provided in the roof, back and throat sheets of the boiler for the insertion of washout nozzles and for inspection. Washout nozzles shall be used as shown in Fig. 15. (b) When locomotives use water that deposits scale the syphons should be ‘Bobbed’ at suitable intervals to remove the deposits, special attention being given to the lower portion or barrel of the syphon on account of solids settling in this part and the probable effect of its nearness to the hottest part of the fire. Bobbing should be done only as often as necessary, the intervals to be determined by local conditions. A standard bobbing tool for thermic syphons should be obtained, the working face of which is shaped to fit the contour of the syphon barrel. This tool should be used in a short stroke air hammer which has sufficient power to dislodge the scale without damaging the syphon. Department of Railways, New South Wales Boiler Maintenance Regulations Page 60

SECTION 20

Safety Valves

20.01 SAFETY VALVE INSPECTOR'S DUTIES: (a) Adjustment of safety valves and issue of certificates: The Safety Valve Inspector shall check and adjust the safety valves of locomotives going out of Eveleigh and Chullora Workshops, and issue certificates for same. (b) Examination, gauging and final adjustment of pop valves: The Safety Valve Inspector shall examine and gauge the parts of all locomotive pop safety valves during the process of assembling at Eveleigh Workshops. He shall see the valves assembled on the bench, test, adjust and seal them with copper wire, and subsequently check this adjustment while the boilers are in steam before the locomotives to which they are fitted are handed over to the Running Section. (c) Standards of maintenance for pop valves: The standards of maintenance for the repair and overhaul of pop safety valves, as shown on the current drawings, shall be strictly adhered to. (d) Damage to pop valves: The Safety Valve Inspector shall be held responsible for bringing under notice any major defects that are observed in pop valves returned from service, especially where it is obvious that the valve casing has been damaged through carelessness, etc. (e) Periodical checking of repairs to Ramsbottom valves: The Safety Valve Inspector shall be responsible for periodically checking the work of repairing, assembling and testing the Ramsbottom valves carried out by the safety valve fitters in Department of Railways, New South Wales Boiler Maintenance Regulations Page 61 the workshops, before fitting to the boilers. (f) Checking Ramsbottom valves under steam: Ramsbottom safety valves shall be checked for correct adjustment by the Safety Valve Inspector when the locomotive is under steam, before it is handed over to the Running Section. Safety Valves

(g) Examination and checking of Westinghouse pump governors, steam gauges and air gauges on locomotives prior to running trial: Locomotives being turned out of the workshops, both at Eveleigh and Cardiff, and before being handed over to the Running Section, shall have the Westinghouse pump governors examined, set at the required pressure, and sealed with copper wire as shown on Drawing No. 27895. The steam gauges and air gauges also shall be checked at this time for correct operation. Any gauge showing an error of 3 lb. or more in the readings when compared with a standard gauge, shall not be used. At the Eveleigh Workshops, the Safety Valve Inspector, or his deputy, shall be held responsible for carrying out this work, and at the Cardiff Workshop, the Officer who is employed on the work or adjusting the safety valves shall be responsible. A record of this work shall be entered in the remarks column of the safety valve certificate for the locomotive concerned as follows:

"Pump Governor No. ____Examined, set and sealed. Steam Gauges______Found correct. Air Gauges______-Found correct." (h) Examination of safety valves of stationary boilers and unfired pressure vessels: The Safety Valve Inspector shall examine and adjust the safety valves of stationary boilers and unfired pressure vessels within the Metropolitan Area, when directed to do so by the Boiler Engineer. (i) Doubtful adjustment of safety valves on locomotives in traffic: The Safety Valve Inspector shall have access to the footplate of any locomotive in traffic to make such examination and test as may, in his opinion, be necessary to determine if the valves are blowing-off at the correct pressure. In the event of there being a defect, he shall immediately telegraph or telephone its nature to the Steamshed Inspector concerned, and thereafter forward to the Boiler Engineer a list of the locomotives so reported. Similarly, Steamshed Inspectors shall report the action taken with respect to the defect or defects so pointed out by the Safety Valve Inspector. (j) Checking safety valve certificates: The Safety Valve Inspector shall check the particulars stated on the safety valve certificates submitted by Works Managers, Steamshed Inspectors, Inspector of Water Supplies and Boiler Inspectors, etc., and collaborate with the Officer on the Boiler Engineer’s staff recording these certificates to ensure that the engine and boiler numbers and working pressures are correct.

20.02 RAMSBOTTOM TYPE VALVES FOR LOCOMOTIVES: Ramsbottom type safety valves shall be provided with ferrules or a liner under the anchor plate, as shown on the drawings. The ferrules or liner shall be cut to the exact Department of Railways, New South Wales Boiler Maintenance Regulations Page 62 height required for the valve to blow-off at the working pressure provided for the boiler in which such safety valves are mounted; when the anchor plate is tightly screwed down on to the ferrules or liner. Ferrules and liners shall be supplied on application to the Clerk in Charge of Country Orders. The condemning size of safety valves of the Ramsbottom type is shown on Drawing No. 36177. The attention of those concerned with the re-seating of valves is directed to the necessity of maintaining the 1/8 in. radius in the wings under the valve face to prevent the valve plugging the column. The valve seat shall be 1/2 in. thick when new, and the valve shall be condemned when the seat thickness is reduced to 1/4 in. The diameter of the valve seat shall be 3/16 in. larger than the valve chamber bore. 20.03 REPAIR, ADJUSTMENT AND RECORD OF RAMSBOTTOM SAFETY VALVES AT EVELEIGH AND CARDIFF WORKSHOPS: The Sub-foreman controlling the employee responsible for the repair and adjustment of Ramsbottom safety valves shall keep a record book showing engine number, boiler number, working pressure adjusted to, length of ferrule or liner, date fitted and repairs carried out to each Ramsbottom valve dealt with. It shall become his duty to personally see that each valve is correctly adjusted under test and to initial the entry as such. The employee carrying out the repairs and fitting the ferrules or liner to their correct height for the pressure required shall stamp the ferrules or liner in the way directed in Clause 20.05. 20.04 OFFICER RESPONSIBLE FOR ADJUSTMENT OF VALVES AT DEPOTS: At depots, the repair and adjustment of Ramsbottom valves and the adjustment of pop valves shall be carried out by the Officer-in-Charge, Sub-foreman Fitter or the Leading Fitter, who shall be held responsible for carrying out the work correctly. When a deputy is appointed, the time he acts as such shall be recorded. 20.05 STAMPING FERRULES OR LINER PLATE FOR RAMSBOTTOM VALVES: Whenever the ferrules or liner under the anchor plate are altered in height to give the correct blowing-off pressure to the valve, the ferrules or liner shall have the following particulars stamped on each end and on the side with 1/8 in. steel dies: Workshop or depot abbreviation date of adjustment initials of employee making the adjustment. 20.06 UNAUTHORISED INTERFERENCE WITH SAFETY VALVES: Interference with the adjustment of safety valves by unauthorised persons is strictly prohibited. Any person who shortens the ferrules or liner, exchanges, removes or alters the adjustment of Ramsbottom, pop, or other type of safety valves without authority, will render himself liable to dismissal. 20.07 DESPATCH OF DEFECTIVE POP SAFETY VALVES TO EVELEIGH WORKSHOPS FOR REPAIRS: When, through wear, pop safety valves become defective, they shall be forwarded to Eveleigh Workshops for re-conditioning. On no account shall repairs to pop valves be attempted at depots. Department of Railways, New South Wales Boiler Maintenance Regulations Page 63

Each pop valve consigned from a depot to Eveleigh Workshops for repairs shall have a metal label attached showing the number of the locomotive from which the valve was removed and the depot concerned. If any unusual feature governs the withdrawal of valve from service, a report shall be forwarded to the Boiler Engineer. 20.08 CORRECT ADJUSTMENT OF SAFETY VALVES: During the testing of safety valves on locomotives, care shall be taken to ensure that all valves blow-off at their correct pressures. Where a locomotive boiler is fitted with Ramsbottom valves and a pop valve, the Ramsbottom valves shall be set to blow off at the registered pressure of the boiler, and the pop safety valve at 3 lb. per sq. in. heavier. On D59 locomotive boilers fitted with 2 pop safety valves only, the right hand or No. 1 valve shall be set at 200 lb. per sq. in. and No. 2 valve or left hand valve shall be set at 202 lb. per sq. in.. On all other locomotive boilers (other than C36 class fitted with copper fireboxes) fitted with 3 pop safety valves only, the No. 3 valve (the one nearest the cab spectacle plate) shall be set to the registered working pressure of the boiler, No. 2 (or middle) valve 2 lb. per sq. in. heavier, and No. 1 (or dome) valve to 5 lb. per sq. in, heavier than the working pressure. On ‘C36’ class boilers fitted with copper fireboxes the No. 2 and No. 3 valves on the top of the firebox shall be set to 185 lb. per sq. in. and the No. 1 valve on the side of the dome to 187 lb. per sq. in.. 20.09 UNAUTHORISED INCREASE OF WORKING PRESSURE: Any person increasing the registered boiler pressure of any locomotive or stationary boiler without the authority of the Chief Mechanical Engineer will be seriously dealt with. 20.10 TESTING SAFETY VALVES AT DEPOTS: At depots, the safety valves on locomotives shall be tested for correct adjustment against a standard test pressure gauge once each month, and at the intermediate boiler test, and at other times should circumstances warrant. When a standard test pressure gauge is not available, a pressure gauge that has previously been checked for accuracy on a Crosby dead-weight testing machine, or against a standard test pressure gauge, and is known to be correct, may be used. Before a test gauge is attached to the drain cock of a water gauge column, the cock shall be opened and blown through to ensure a clean passage. The observance of this precaution will prevent foreign matter that may, be lodged in the passage above the cock being blown into the mechanism of the gauge. A record of the checking of safety valves shall be entered in the mechanical record book and on the monthly engine and boiler form (X469). 20.11 SEALING POP SAFETY VALVES: When an adjustment is made to the blowing-off pressure of a pop safety valve, the valve, after final adjustment, shall be sealed by means of a lead seal and copper wire as shown on Drawing No.40654. The dies in the hand press used for closing the seals shall bear the abbreviation of the name of the depot concerned. Lead seals shall be supplied by the Comptroller of Stores on requisitions. These requisitions shall be made out for ‘seals (copper wire) for pop safety valves’ and be submitted by District Locomotive Engineers through the Locomotive Accountant, and by the Locomotive Works Manager, direct to No. 15 Store, Eveleigh. Department of Railways, New South Wales Boiler Maintenance Regulations Page 64

20.12 DEPOT NAME ABBREVIATIONS: The following distinguishing abbreviations of Depot names shall be used for stamping safety valve seals:

Albury ALB. Eveleigh ER. Orange OR Running Shed N. Armidale ARM. Enfield ENF Parkes PA . R. Bathurst BX. Goulburn GB Port Kembla PT N. K. Broken Hill BH. Griffith GTH Port Waratah PW . . Broadmeadow BMD. Glenreagh GLR Penrith PE . N. Binnaway BNW. Hornsby HRN Picton PIC . . Clyde CLY. Harden HDN Singleton SG . L. Cowra CRA. Ivanhoe IVH. South Grafton GR F. Cootamundra CTA. Junee JUN Thirroul TH . R. Casino CAS. Lithgow LTH Temora TE . M. Cardiff Shops CDF. Murrurundi MR Taree TR R. E. Cooma COM. Muswellbrook MB The Rock RO K. C. Culcairn CUL. Moree MR Tamworth TA E. West M. Chullora Loco. CHL. Mudgee MU Tenterfield TN Shops D. F. Dubbo DUB. Narrandera NRR Tocumwal TO . C. Eveleigh ES. Nyngan NYN Valley Heights VY Shops . H. Narrabri West NBR Werris Creek WC . K. Yeerongpilly YP L. ISSUE OF SAFETY VALVE CERTIFICATES: Where repair or adjustment of Ramsbottom valves or replacement or adjustment of pop safety valves is required, a safety valve certificate (X1670) shall be carefully and correctly filled in and signed by the Safety Valve Inspector, Officer-in-Charge or Leading Fitter, and forwarded to the Works Manager or Steamshed Inspector, as the case may be. The latter Officers shall endorse the certificates and forward them to the Boiler Engineer each week. It shall be noted that the repairs carried out to a Ramsbottom valve shall be shown in the remarks column of the certificate. If a pop valve is changed from one boiler to another, or adjusted, the registered number of the pop valve and the reason for removal or adjustment shall be stated in the remarks column of the certificate. Department of Railways, New South Wales Boiler Maintenance Regulations Page 65

20.14 ISSUE OF POP SAFETY VALVES: No. 1 Workshop Store, Eveleigh, shall control the issue of all new and repaired pop safety valves to workshops and depots. When ordering valves, the size and type of valve required, and the approved working pressure of the boiler to which it is to be fitted, shall be stated. The safety valves, as issued, shall be sealed and tagged with the number of the valve and the pressure to which the valve is set. When the valve is fitted to the boiler, it shall be tried under steam by the employee responsible for the inspection and adjustment of safety valves at the depot. If the valve does not blow-off at the correct pressure, the seal shall be broken and the valve adjusted correctly before the locomotive is passed for service. 20.15 EXAMINATION AND TESTING OF STEAM GAUGES AT DEPOTS: The checking of steam gauges on locomotive boilers shall be carried out at the monthly boiler examination, during the time the safety valves are being tested. Each gauge shall be compared with the standard test gauge, or its equivalent, as provided for in Clause 20.19. The date of checking shall be recorded on the monthly report form (X469). Any steam gauge found to vary by more than 3 lb. from the reading of the standard gauge shall have the hand correctly adjusted. The gauge shall then be checked again. If incorrect reading still occur, or it is obvious that mechanical defects are present, the gauge shall be despatched to the Locomotive Works Manager for repair. The internal mechanism of the gauge shall not be interfered with at a Depot. The checking of drifting gauges shall be carried out at the same time as boiler gauges are checked, the steam valve at the steam pipe being shut off and the union underneath the gauge disconnected. In the normal position the indicator should read 2 inches of mercury on the vacuum side of the zero mark, and, if necessary, the indicator shall be removed and adjusted to give this reading. 20.16 DAMAGE TO STEAM PRESSURE GAUGES IN TRANSIT: District Locomotive Engineers shall issue instructions to those concerned that pressure gauges despatched to the workshops for repair shall be in a clean condition. Each gauge shall have a tin label attached stamped with the abbreviated name of the depot concerned, and be carefully packed and protected against further damage in, transit. A serious view will be taken of any neglect to carry out this instruction. 20.17 STANDARD TEST GAUGES: Standard test gauges held at workshops, depots and by Boiler Inspectors, and used for the purposes of checking boiler pressures, adjustment of safety valves and the testing of pressure vessels, etc., shall be checked for correct reading every 3 months on a Crosby dead-weight testing machine. The following workshops and depots have Crosby dead-weight testing machines: Eveleigh and Cardiff Workshops.Goulburn, Casino, Werris Creek and Bathurst Depots. The maximum permissible error of a standard test gauge, when being checked on a Crosby testing machine, shall be 2 lb. between the pressures of 135 and 210 lb. per square inch. When a gauge is found to vary by more than this margin, or where it is evident that mechanical defects are present, the gauge shall be despatched to the Locomotive Works Manager for repair. No interference with the mechanism of standard test gauges shall be permitted. District Locomotive Engineers shall be responsible for seeing that their standard test gauges are carefully packed and sent to the nearest workshop or depot mentioned on page 85 for checking every three months, or whenever variations occur in the readings Department of Railways, New South Wales Boiler Maintenance Regulations Page 66 of both hands, or other defects arise which would render the gauge inaccurate. During the time a standard test gauge is away from a depot for checking, a spare steam gauge, having a 50 per cent. margin in its capacity for the pressure to be tested, and which has previously been checked against the standard test gauge, and is known to be correct, shall be used. At out-depots where an ordinary steam gauge is used, it shall be changed at two- monthly periods with a checked gauge from the home depot. The Officer-in-Charge shall depute his Sub-foreman or Leading Fitter to keep a record of the number of the standard gauge at the depot, and the dates on which it is checked on a Crosby testing machine. Regulations covering the Inspection and Repair of Stationary and Portable Boilers.

21.01 EXAMINATIONS BY BOILER INSPECTORS: Boiler Inspectors shall carry out the examination of all stationary or portable boilers in the service of the Department of Railways (except those under the control of the Chief Electrical Engineer) due for internal examination or major repairs. The boilers shall be examined at the usual periods as described herein. The dates when boilers are due for examination shall be advised by Return No. 13. Boiler Inspectors shall arrange with the Steamshed Inspectors for the preparation of boilers for examination, and for the necessary repairs and tests. The repairs required, as disclosed at the examination, shall be reported on a repair form (X2882). A copy of the repair form shall be served upon the authority in control of the boiler, and he shall arrange for the necessary attention to be given. The Boiler Inspector shall endorse this form to suspend the currency of the certificate during the time the boiler is out of service. When the repairs and hydrostatic test have been satisfactorily completed, the Boiler Inspector shall endorse the repair form to this effect. The original repair form and the original and copy of the report upon subsequent inspection, shall be forwarded to the Boiler Engineer. When approved, the copy of the report upon subsequent inspection shall be forwarded to the Steamshed Inspector or Officer-in-Charge for attaching to the boiler history record, together with the copy of the repair form. 21.02 COMPLETION OF REPAIRS AND TESTS: The Boiler Inspector shall be held responsible for seeing that all repairs to the boiler are completed in a satisfactory manner. All tests shall be carried out under his supervision. 21.03 FILING OF REPORTS: A history record file, containing copies of the reports on examinations, repairs, etc., and the service certificate for each boiler, shall be maintained, and where practicable, displayed in a frame in the boiler house. The frame shall have a glazed door hinged to a box frame about 1 in. deep and be screwed to a support in such a position that the file will be away from the effects of dirt, water and oil at all times. It is important that the file shall be kept clean. The frame shall be locked and the key held by the Boiler Attendant whilst on duty, and he shall be responsible for its safe custody and availability to the Boiler Inspector, Steamshed Inspector or Officer in control for reference to the file when required. Department of Railways, New South Wales Boiler Maintenance Regulations Page 67

Where it is not practicable to display the certificate in the boiler house, the certificate and history record file shall be held by the Steamshed Inspector or other authority controlling the boiler. The Steamshed Inspector or other authority in control of the boiler shall be responsible for filing all forms forwarded to him in connection with the boiler. A boiler shall not be allowed to remain in service under steam pressure unless it has attached to its history record file a current service certificate. 21.04 BOILERS DUE FOR EXAMINATION: Arrangements, to suit the local conditions of working, shall be made by those concerned for the early examination of a boiler immediately advice of the date it is due for examination is received from the Boiler Engineer. Four weeks shall be the maximum time allowed after the expiration of the service certificate for the completion of the examination, but every endeavour shall be made to have the boiler ready for examination before the date of expiry of the service certificate. The Steamshed Inspector or other authority in whose district the boiler is to be examined, shall arrange with the Boiler Inspector for the most suitable time to carry out the examination, or advise the Boiler Engineer, giving at least two days’ notice when the boiler will be ready for examination. 21.05 EXAMINATION FOR DEFECTS AT PERIODICAL FUSIBLE PLUG INSPECTION. At each fusible plug examination, the Leading Boilermaker of the depot from which the boiler is controlled, or other person carrying out this work shall peruse the history file of the boiler, and note any defects or other weaknesses, etc., stated thereon. He shall make an examination of the condition of the boiler generally, and give special attention to any defects or other weaknesses, etc., stated in the last report by the Boiler Inspector, to determine if any extension has taken place. Any serious defects discovered that would affect the safe working of the boiler shall be reported to the Boiler Engineer, also, any repairs found necessary shall be carried out and reported in writing. 21.06 SAFETY VALVES PERIODICAL CHECKING OF THE OPERATION OF: Where minor defects are found to exist in the operation of the valves the local safety valve fitter or other competent fitter should carry out the repairs, but in all other cases the valves should be changed for one in good condition. At all times, however, when an adjustment is made to safety valves on a stationary boiler the valve should be sealed by means of a lead seal and copper wire and the Boiler Engineer informed by memo. of the adjustments made. Maintenance Regulations for Stationary and Portable Boilers

22.01 NUMBER TABLETS: Every stationary and portable boiler in the service of the Department of Railways, with the exception of those controlled by the Chief Electrical Engineer, shall have a cast brass number tablet affixed to the boiler by studs screwed into the boiler plate close to the water gauge cocks. The studs shall not be fitted with nuts, but be cut off short and riveted over the number tablet. 22.02 STAMPING NUMBER ON BOILER: The number of each boiler shall be stamped on the boiler plate, in addition to being shown on the number tablet. Department of Railways, New South Wales Boiler Maintenance Regulations Page 68

22.03 NUMBER TABLETS FOR NEW BOILERS: When boilers are to be placed in stationary service for the first time, a number tablet shall be affixed during the time the boiler is being prepared for service. 22.04 ISSUE OF NUMBER TABLETS: The issue of number tablets shall be controlled by the Boiler Engineer, and application shall be made to this Office when new tablets are required. 22.05 REMOVAL OF NUMBER TABLETS FROM CONDEMNED BOILERS: When a boiler is condemned, the number tablet shall be detached immediately and forwarded to the Boiler Engineer. The boiler shall be marked clearly in paint with the word ‘CONDEMNED’. 22.06 FUSIBLE PLUG EXAMINATION PERIODS: The fusible plugs fitted in stationary and portable boilers shall be examined by Boiler Inspectors when conducting their periodical examinations. Any plugs found defective are to be renewed. Intermediate between these examinations (6 or 7 months, as the case may be) the Leading Boilermaker, if available, otherwise a competent boilermaker, shall examine the plugs and, renew them if found defective. The test grooves in boilers with longitudinal lap seams shall also be examined during the fusible plug examination as provided for in Clause 24.08. A record shall be kept of all such examinations. 22.07 REGULATIONS GOVERNING ATTENDANTS OF STATIONARY AND PORTABLE BOILERS:

The following regulations shall be strictly observed in. connection with persons employed attending to Departmental steam boilers: (a) No person shall act in the capacity of Boiler Attendant in charge of any stationary portable or steam boiler unless he is the holder of a Boiler Attendant’s Certificate. A certificated locomotive driver or fireman may be used, provided not more than 2 years has elapsed since he has been employed as a driver or fireman. In the case of an employee, who has previously qualified for the position of locomotive driver or fireman, and who has not been used as such for a period of more than 2 years and not in excess of 5 years, he is to be orally examined by a Boiler Inspector as to his competency before being utilised as a stationary Boiler Attendant. If an employee who has previously qualified for the position of locomotive driver or fireman, and has not been used in such calling in excess of 5 years, he will be required to sit for a written examination and obtain a Boiler Attendant’s Certificate before he can act as a Boiler Attendant. (b) No employee under the age of 18 years is eligible for a Boiler Attendant’s Certificate. (c) To provide for relief, sickness or other unforeseen circumstances, of the usual certified Boiler Attendant’s services, it shall be necessary to have available another employee holding the proper certificate or qualification to carry out the work when required. (d) Any Boiler Attendant, while in charge of a steam boiler, who absents himself from his charge, and any responsible Officer controlling the plant who requires him to so absent himself without providing for the proper relief, shall be held responsible for such action. (e) No Boiler Attendant shall be considered to be in charge of any steam boiler unless he is always within safe distance of the boiler while it is under working Department of Railways, New South Wales Boiler Maintenance Regulations Page 69 conditions. 22.08 REGULATIONS GOVERNING CONTRACT PAMPERS WORKING AS ATTENDANTS IN CHARGE OF STEAM PLANTS: In the employment of Contract Pumpers to take charge of steam plants, the following instructions shall be observed, and all concerned shall be advised of what is required: (a) Only approved Contract Pumpers who have been examined by a Boiler Inspector and certified as competent to perform the duties required shall be placed in charge of steam pumping plants. Maintenance Regulations for Stationary and Portable Boilers.

(b) In the event of a Contract Pumper being unable, for any reason, to carry out his contract duties, he shall immediately communicate with the District Locomotive Engineer in charge of the district, whose duty it shall be to provide as a substitute for the period concerned, a duly qualified Departmental employee. For the period in which a Contract Pumper does not perform his contract duties, his payment shall be reduced in accordance with the terms of the contract conditions. (c) In no circumstances shall permission be given to a Contract Pumper to appoint his own substitute when the conditions detailed in Paragraph (b) of this instruction arise. 22.09 REMOVAL OF LAGGING FOR EXAMINATION OF STATIONARY AND PORTABLE BOILERS: At the following periods, the lagging shall be removed from the shell plates of boilers to allow a close examination to be made of the external condition of the plates and seams, etc.:

Period for Removal of Type of Boiler Lagging Locomotive At each internal examination For new boilers – at the age Colonial; Loco. Portable; of 5 years. Thereafter Horizontal internally fired every 6 years, or at every return tube second internal examination Every fourth internal Babcock & Wilcox ; Vertical ; examination All other types (approximately 5 years)

22.10 LAGGING ON STATIONARY AND PORTABLE BOILERS: The asbestos lagging on boilers shall not be painted with Biturine, Woolene or tar, as this prevents its re-use after being removed for the examination of the boiler. If the lagging becomes discoloured through smoke, etc., it can readily be cleaned by using a wash made of asbestos thinned with water. A small quantity of asbestos shall be retained at the boiler house for the purpose of making the cleaning wash, and for use in making repairs to the lagging should it become defective at any time. Department of Railways, New South Wales Boiler Maintenance Regulations Page 70

22.11 TIME ALLOWANCE FOR WASHING OUT STATIONARY BOILERS: Where stationary boilers cannot be washed out within the ordinary hours of duty, the time allowance for the work shall be as follows: Washing out vertical boilers 2 hours. Washing out Loco, Horizontal internally fired return tube and colonial type boilers 3 hours. The work of washing out shall include the removal of blown-down cocks, water gauge cocks, try cocks, manhole and mudhole doors and washout plugs; the cleaning and greasing of cocks and plugs where necessary, and re-making of joints; the testing and cleaning of the water ways in water gauges, and re-filling the boiler. The times quoted above are for the guidance of District Locomotive Engineers or officers in control, but if, in their opinion, local conditions warrant more time, this may be allowed at their discretion. 22.12 RESPONSIBILITY FOR SAFE-WORKING: The Works Manager, District Locomotive Engineer, or the Officer in control of the workshop, district or depot where stationary boilers are in service, shall be responsible for the safe-working of such boilers during the interval between Boiler Inspector’s examinations. 22.13 MAINTENANCE OF BOILERS BY BOILER ATTENDANTS: The District Locomotive Engineer or Officer in control shall see that Boiler Attendants carry out their duties efficiently. Boilers shall be washed out regularly and the fittings kept in order. The boiler surroundings shall be kept clean and tidy, and all defects attended to and satisfactorily repaired. 22.14 EXAMINATION PERIODS FOR STATIONARY AND PORTABLE BOILERS: Type of Boiler Internal Examination Intermediate Examinations Locomotive 1st at age of 6 years. 1st at age of 3 years. Thereafter every 3 2nd at age of 4½ years. years Thereafter every 12 months between internal examinations Locomotive portable ; 1st at age of 5 years. Every 12 months between Colonial ; Thereafter every 3 internal examinations Horizontal internally years fired return tube Babcock & Wilcox ; Every 14 months ___ Wolf; Vertical ; Sentinel Wagon ; Hot Water Heaters

22.15 OPPORTUNITY FOR INTERIOR INSPECTION AT INTERMEDIATE EXAMINATIONS: Where the construction of a boiler will permit, the Boiler Inspector shall enter the barrel and examine the internal surfaces of plates and tubes at the intermediate examinations. Every endeavour shall be made to inspect as much of the inside of a boiler as possible. Department of Railways, New South Wales Boiler Maintenance Regulations Page 71

23.01 HYDROSTATIC TESTS: Before new boilers, in which all the main joints are riveted, are put into service, they shall he tested hydrostatically to a pressure equivalent to the working pressure plus 50 per cent. Boilers other than new, in which all the main joints are riveted, when tested at examination periods, shall be subjected to a hydrostatic pressure equivalent to the working pressure plus 25 per cent. The hydrostatic test shall be made with water at a temperature of approximately 1500 F. Before applying the pressure, the boiler shall be completely filled with water to displace all the air. The pressure shall be applied steadily and, when the test pressure is reached, it shall be maintained for a period of 15 minutes. A thorough examination shall be made of the boiler while it is subject to the test pressure. All flat surfaces shall be inspected for signs of bulging or distortion, and all joints, stays, tubes, rivets, plugs, seatings, etc., examined for signs of leakage or other defects. 23.02 STEAM TESTS: After the hydrostatic test has been completed and before the issue of a certificate, every newly registered boiler and every boiler on which major repairs have been carried out shall be tested by gradually raising steam in the boiler to a pressure equivalent to the working pressure, plus 10 per cent. This test pressure shall be maintained for 15 minutes, after which steam shall be blown off until the pressure is reduced to the approved working pressure. The working pressure shall be maintained for 15 minutes. During the periods in which the test pressure and the working pressure are maintained, the boiler shall be carefully examined for any signs of leakage or evidence of distress arising from the temperature changes following the variation in the pressure. Throughout the steam test, the safety valves shall be free and capable of being adjusted to meet the requirements of the variation in pressure. 23.03 ACCUMULATION TEST FOR DISCHARGE CAPACITY OF SAFETY VALVES: After the completion of the steam test on every newly constructed boiler, and whenever an alteration is made in the approved working pressure of an existing boiler, an accumulation test shall be carried out to determine the capability of the safety valves to prevent an accumulation of pressure. The test shall be made under full steam and maximum firing conditions, with the stop valve closed, and the feed water cock shut. For shell type boilers, the period of test shall be 15 minutes, and for water-tube boilers, as long as the water supply in the boiler permits, with a maximum of 7 minutes. During this test, the accumulation of pressure shall not exceed 10 per cent. of the maximum allowable working pressure. The Inspector shall note the accumulation of pressure and other details of the test, as well as the loading and operation of the safety valves. If the accumulation of pressure at a steam test exceeds 10 per cent. of the maximum working pressure, the area of the safety valves shall be considered insufficient, and a certificate shall not be issued until the safety valve area is increased and the accumulation test satisfactorily passed. On no account shall the steam pressure be allowed to rise more than 5 lb. per sq. in. above the 10 per cent. margin during an accumulation test. Department of Railways, New South Wales Boiler Maintenance Regulations Page 72

23.04 SETTING SAFETY VALVES: The safety valves shall be adjusted and set after the completion of the steam and accumulation tests, where made, or during the first period the boiler is steamed subsequent to the hydrostatic test.

Examination of Boilers and Unfired Vessels having Longitudinal Lap Seams

24.01 CUTTING TEST GROOVES: In order to indicate if grooving or fractures develop in barrel plates adjacent to the inside edges of longitudinal lap seams, so that at all times the greatest margin of safety will exist, test grooves shall be cut over these seams in the outside of the barrel plates of all boilers and those unfired pressure vessels having a diameter of two feet or greater. In existing boilers and unfired pressure vessels not previously dealt with, the grooves shall be cut when the next examination is made. The test grooves shall be cut with a round-nose chisel not more than 3/16 in. wide, to a depth equivalent to 50 per cent. of the shell plate thickness. The length of the groove and its position in relation to the seam shall be as shown in Figs. 24 and 25 of the appendix. The work shall be carried out under the direction and supervision of a Boiler inspector. 24.02 EXAMINATION OF TEST GROOVES UNDER HYDROSTATIC PRESSURE. After the test grooves have been cut, the boiler or unfired pressure vessel shall be hydrostatically tested and the grooves carefully examined while the vessel is under pressure, for signs of leakage through the grooves. If no sign of leakage is apparent, the boiler or unfired pressure vessel shall again be placed in service. If leakage does occur through the test grooves while the boiler or unfired pressure vessel is under hydrostatic pressure, the matter shall immediately be reported to the Boiler Engineer, and the boiler or unfired pressure vessel kept out of service. The subsequent action to be taken shall be directed by the Boiler Engineer. 24.03 RECORDING POSITIONS OF TEST GROOVES: A sketch showing the positions of the test grooves which have been cut in each course of the barrel shall be attached to the inspection report form. 24.04 PROVISION OF LABOUR AND EQUIPMENT FOR CUTTING TEST GROOVES: District Locomotive Engineers and other Officers in control of boilers and unfired pressure vessels shall provide the labour and tools for cutting test grooves to the dimensions shown in Fig. 25 of the appendix (also shown on Drawing No. 39443). 24.05 SIGHT HOLES IN LAGGING AND BRICKWORK TO PERMIT INSPECTION OF TEST GROOVES: Boilers with test grooves cut in the shell plates shall have the lagging near the test grooves cut away to provide a clear view for inspection: Where test grooves are covered by brickwork, a channel shall be cut in the brickwork around the grooves if possible, or loose bricks fitted, to provide a means of detecting leakage from the grooves. Department of Railways, New South Wales Boiler Maintenance Regulations Page 73

24.06 REGULAR EXAMINATION OF TEST GROOVES BY ATTENDANT IN CHARGE OF BOILERS OR UNFIRED PRESSURE VESSELS. Where sight holes are provided in lagging and brickwork, or loose bricks are fitted to give access to test grooves, the grooves shall be examined daily by the attendant to defect any signs of leakage while the boiler or unfired pressure vessel is under pressure. District Locomotive Engineers and other Officers in control of boilers and unfired pressure vessels shall indicate the positions of the grooves to the attendants and instruct them in the examination of the grooves, and the action to be taken if leakage develops, as provided for herein. 24.07 EXAMINATION OF TEST GROOVES WHEN SIGHT HOLES ARE NO PROVIDED: Where it is not practicable to provide sight holes or loose bricks to give access to test grooves, the matter shall be reported on the usual inspection reports and arrangements made with the Officer in control of the boiler or unfired pressure vessel for periodical examinations of the grooves by a competent man.

24.08 EXAMINATION OF TEST GROOVES AT WASHOUT PERIODS AND FUSIBLE PLUG EXAMINATIONS: For boilers located at Depots, the Sub-foreman or Leading Boilermaker shall examine the test grooves at each washout period. Boilermakers, when carrying out fusible plug examinations, shall also examine the test grooves, especially those covered by brickwork. Whenever a boilermaker is engaged on work at a boiler away from a depot, he shall examine all test grooves. 24.09 ACTION TO BE TAKEN WHEN TEST GROOVES LEAK IN SERVICE: If leakage occurs at a test groove, the boiler or unfired pressure vessel shall be closed down immediately and the matter reported to the Boiler Engineer. The vessel shall be kept out of service pending receipt of instructions from the Boiler Engineer. Any arrangements necessary to meet the position, due to a boiler stoppage, shall be made. 24.10 DRILLING CORE HOLES FOR FURTHER EXAMINATION OF PLATE: When instructions are given by the Boiler Engineer for the drilling of core holes, subsequent to leakage from test grooves, the work shall be carried out under the supervision of a Boiler Inspector. The positions of the core holes in the seam shall be as shown in Figs. 24 and 25 of the appendix (also shown on Drawing No. 39943), or in other positions as directed. The equipment for drilling core holes is available at the Office of the Boiler Engineer, and shall be despatched to the Boiler Inspector when required. The use of a pilot hole for the core drill is illustrated in Fig. 25 of the appendix, and the arrangement of drilling post and ratchet for drilling core holes is shown in Fig. 27 of the appendix. The walls of the holes and the cores removed shall be carefully examined under a magnifying glass for signs of grooving or fractures existing in the plate. The cores shall be labelled to indicate the positions from which they were removed, and forwarded to Department of Railways, New South Wales Boiler Maintenance Regulations Page 74 the Boiler Engineer, together with a report of the examination and a sketch showing the positions of the test grooves and core holes. All labour necessary for the drilling of core holes shall be provided by the District Locomotive Engineer, or Officer in control of the vessel.

SECTION 25 Regulations covering the Inspection, Repair and Testing of Unfired Pressure Vessels

25.01 SCOPE: The Regulations in this Section cover all air reservoirs, gas reservoirs and unfired pressure vessels in the service of the Department of Railways, with the exception of the following: (a) Equipment controlled by the Chief Electrical Engineer. (b) Air reservoirs used for braking systems on locomotives and rolling stock. (c) Gas reservoirs used for lighting and heating purposes on rolling stock. 25.02 EXAMINATION BY BOILER INSPECTORS: Unfired pressure vessels shall be examined by a Boiler Inspector at the usual periods, as described herein. The dates when vessels are due for examination shall be advised by Return No. 17. Boiler Inspectors shall arrange with the Steamshed Inspectors, or other authority in control, for the preparation of vessels for examination and for the necessary repairs and tests. The repairs required, as disclosed at the examination, shall be reported on a repair form (X2882). A copy of the repair form shall be served upon the authority in control of the vessel and he shall arrange for the necessary attention to be given. The Boiler Inspector shall endorse this form to suspend the currency of the certificate during the time the vessel is out of service. When the repairs and hydrostatic test have been satisfactorily completed, the Boiler Inspector shall endorse the repair form to this effect. The original repair form and the original and copy of the report upon subsequent inspection shall be forwarded to the Boiler Engineer. When approved, the copy of the report upon subsequent inspection shall be forwarded to the Steamshed Inspector or Officer-in-Charge for attaching to the history record of the pressure vessel, together with the copy of the repair form. 25.03 COMPLETION OF REPAIRS AND TESTS: The Boiler Inspector shall be held responsible for seeing that all repairs to the pressure vessel are completed in a satisfactory manner. All tests shall be carried out under his supervision. 25.04 FILING OF REPORTS: A history record file, containing copies of the reports on examinations, repairs, etc., and the service certificate for each unfired pressure vessel, shall be maintained, and where practicable, displayed in a frame in a suitable location near the vessel. The frame shall have a glazed door hinged to a box frame about 1 in. deep and be screwed to a support, in such a position that the file will be away from the effects of dirt, water and oil at all times. It is important that the file shall be kept clean. The frame shall be locked and the key held by the Officer-in-Charge, and he shall be responsible for its safe Department of Railways, New South Wales Boiler Maintenance Regulations Page 75 custody and availability to the Boiler Inspector for reference to the file when required. Where it is not practicable to display the certificate near the pressure vessel, the certificate and history record file shall be held by the Steamshed Inspector or other Authority in control of the vessel. The Steamshed Inspector, or other authority in control of the pressure vessel shall be responsible for filing all forms forwarded to him in connection with the vessel. An unfired pressure vessel shall not be allowed to remain in service under pressure unless it has attached to its history record file a current service certificate. 25.05 VESSELS DUE FOR EXAMINATION: Arrangements, to suit the local conditions of working, shall be made by those concerned for the early examination of a pressure vessel immediately advice of the date it is due for examination is received from the Boiler Engineer. Four weeks shall be the maximum time allowed after the expiration of the service certificate, for the completion of the examination, but every endeavour shall be made to have the vessel ready for examination before the date of expiry of the service certificate. The Steamshed Inspector or other authority in control of the vessel to be examined shall arrange with the Boiler Inspector for the most suitable time for the examination to be made, or advise the Boiler Engineer, giving at least two days’ notice, when the vessel will be ready for examination. 25.06 DRAINAGE OF AIR RESERVOIRS: All air reservoirs covered by these regulations shall be drained regularly whilst in service; daily, if accessible, but under no circumstances less than once a week. 25.07 PROTECTION FROM FIRE: Air reservoirs, gas reservoirs and other unfired pressure vessels shall be protected from fire and the effects of heat, by the removal of combustible material from their surroundings within a radius of not less than 12 feet. 25.08 TEST GROOVES: All unfired pressure vessels having a diameter of 2 feet or greater, and constructed with longitudinal lap seams in the barrel, shall have test grooves cut over the seams. The grooves shall be cut and regular inspection maintained, as provided for in Section 24. 25.09 NUMBERING AND CLASSIFICATION OF UNFIRED PRESSURE VESSELS: Each pressure vessel shall carry a registered number, which shall be stamped with 3/8- inch figures on the barrel or shell plate in a suitable position. In addition, each vessel shall have a cast brass number tablet affixed to it. The Class of service under which unfired pressure vessels are working, shall be indicated on the number tablet by a letter preceding the registered number. The prefix letters shall be as follows: Letter Prefixed to Class of Service Registered Number Air Reservoirs A Gas Reservoirs G Unfired Steam Reservoirs S Calorifiers C Department of Railways, New South Wales Boiler Maintenance Regulations Page 76

Regulations covering the Inspection, Repair and Testing of Unfired Pressure Vessels.

25.10 NUMBER TABLETS FOR NEW PRESSURE VESSELS: When new unfired pressure vessels are to be placed in service for the first time, a number tablet shall be affixed during the time the vessel is being prepared for service. 25.11 ISSUE OF NUMBER TABLETS: The issue of number tablets shall be controlled by the Boiler Engineer, and application shall be made to this Officer when new tablets are required. 25.12 UNREGISTERED VESSELS: Any unfired pressure vessel discovered without a registered number, but which comes within the scope of these regulations as defined in Clause 25.01, shall be reported to the Boiler Engineer by the Officer in control of the vessel. The necessary action shall then be taken to have the vessel registered, examined and tested in accordance with these regulations. 25.13 REMOVAL OF NUMBER TABLETS FROM CONDEMNED PRESSURE VESSELS. When an unfired pressure vessel is condemned, the number tablet shall be detached immediately and forwarded to the Boiler Engineer. The vessel shall be marked clearly in paint with the word ‘CONDEMNED’. 25.14 NEW DESIGNS: Details of all new unfired pressure vessels under review shall be submitted to the Chief Mechanical Engineer before purchase or acceptance, so that the design and construction can be carefully checked and the necessary tests carried out before taking over. All designs of unfired pressure vessels proposed to be manufactured by the Department of Railways, other than for the Chief Electrical Engineer, shall be submitted to the Chief Mechanical Engineer for his consideration and recommendation. 25.15 EXAMINATION PERIODS: Unfired pressure vessels shall be due for examination at the expiration of the time limits set out below: Type of Vessel Examination Period

Air Reservoirs Every 3 years Calorifiers Every 3 years Gas Reservoirs Every 3 years Steam Reservoirs Every 12 months

25.16 LOCAL PERIODICAL EXAMINATIONS: The Locomotive Works Manager, Eveleigh; Works Manager, Carriage Works, Eveleigh; Works Manager, Cardiff; Works Manager, Electric Car Shops, Chullora; Works Manager, Wagon Works, Clyde; Assistant Engineer, Water Supply and Maintenance; Gas Superintendent, District Locomotive Engineers and other Officers in control of unfired pressure vessels, shall arrange for periodical external examinations of such vessels and their mountings, as are located at their respective workshops, depots or districts, at intervals of not less than 12 months and they shall remedy any defects that may have developed since the examination by the Boiler Inspector. Department of Railways, New South Wales Boiler Maintenance Regulations Page 77

25.17 SAFETY OF VESSELS: If a serious defect develops and affects the safety of an unfired pressure vessel, the matter shall be brought immediately under the notice of the district Boiler Inspector for attention, or reported direct to the Boiler Engineer. 25.18 MAINTENANCE OF UNFIRED PRESSURE VESSELS: The Officer in control of an unfired pressure vessel shall be responsible for the maintenance and efficiency of the vessel, including the safety valves and mountings, between the Boiler Inspector’s examinations. 25.19 LOCATION: Changes in the location of pressure vessels shall be reported to the Boiler Engineer on the usual printed form provided for the purpose. 25.20 HYDROSTATIC TESTS FOR VESSELS OF RIVETED OR SOLID DRAWN CONSTRUCTION: Unfired pressure vessels in which all the main seams are riveted or the shells are of solid drawn or cast construction, when being tested for the first time, shall be subjected to a hydrostatic pressure equivalent to the working pressure plus 50 per cent. For subsequent tests, the test pressure shall be equivalent to the working pressure plus 25 per cent. 25.21 HYDROSTATIC TESTS FOR VESSELS OF WELDED OR BRAZED CONSTRUCTION: Unfired pressure vessels, in which any of the main seams are formed by any welding process, or by brazing, when being tested for the first time, and for subsequent tests, shall be subjected to a hydrostatic pressure equivalent to twice the working pressure. 25.22 HAMMER TESTS OF WELDED VESSELS: All unfired pressure vessels, in which any of the main seams are fabricated by means of welding or brazing, shall be hammer tested while the vessel is under the hydrostatic test pressure. The hammer test shall consist of striking the plate with sharp swinging blows, at intervals of six (6) inches, on both sides of the welded joint for the full length of the seam. The weight of the hammer in pounds shall approximately equal the thickness of the shell in tenths of an inch, but not exceed ten (10) pounds. The edges of the hammer shall be rounded to prevent the plates being defaced. 25.23 VESSELS DEFECTIVE UNDER TEST: If an unfired pressure vessel, during any of the foregoing tests, shows any signs of leakage or weakness in any part, gives any indication of opening at any seam or joint, or discloses any other defect which, in the opinion of the Boiler Inspector conducting the test renders the vessel unfit for the proposed working pressure, the defects shall be made good or the pressure reduced to a safe limit. 25.24 SAFETY VALVES – PERIODICAL CHECKING OF THE OPERATION OF: Where minor defects are found to exist in the operation of the valves the local safety valve fitter or other competent fitter should carry out the repairs, but in all other cases the valves should be changed for one in good condition. At all times, however, when an adjustment is made to safety valves on an unfired pressure vessel the valve should be sealed by means of a lead seal and copper wire and the Boiler Engineer informed by memo. of the adjustments made. Department of Railways, New South Wales Boiler Maintenance Regulations Page 78

25.25 GREASING JOINTS OF MAN HOLES, INSPECTION OPENINGS, SCREWED PLUGS AND COCKS. See paragraph 16.12, page 51a-Graphite lubricant. APPENDIX Department of Railways, New South Wales Boiler Maintenance Regulations Page 79 Department of Railways, New South Wales Boiler Maintenance Regulations Page 80 Department of Railways, New South Wales Boiler Maintenance Regulations Page 81 Department of Railways, New South Wales Boiler Maintenance Regulations Page 82 Department of Railways, New South Wales Boiler Maintenance Regulations Page 83 Department of Railways, New South Wales Boiler Maintenance Regulations Page 84 Department of Railways, New South Wales Boiler Maintenance Regulations Page 85 Department of Railways, New South Wales Boiler Maintenance Regulations Page 86 Department of Railways, New South Wales Boiler Maintenance Regulations Page 87 Department of Railways, New South Wales Boiler Maintenance Regulations Page 88 Department of Railways, New South Wales Boiler Maintenance Regulations Page 89 Department of Railways, New South Wales Boiler Maintenance Regulations Page 90 Department of Railways, New South Wales Boiler Maintenance Regulations Page 91 Department of Railways, New South Wales Boiler Maintenance Regulations Page 92 Department of Railways, New South Wales Boiler Maintenance Regulations Page 93 Department of Railways, New South Wales Boiler Maintenance Regulations Page 94 Department of Railways, New South Wales Boiler Maintenance Regulations Page 95 Department of Railways, New South Wales Boiler Maintenance Regulations Page 96